Methods of delivering an oral care active by administering oral care articles comprising a filament

ABSTRACT

A method of delivering a health care active having the steps of administering to a mammal in need of a health benefit or a treatment for a health condition a personal health care article and consuming the article. The article contains one or more filaments that contain a backbone material, a health care active and optionally aesthetic agents, extensional aids, plasticizers, and crosslinking agents.

FIELD OF THE INVENTION

The present invention relates to oral care compositions that deliveractive agents into the oral cavity in the form of an article that is adissolvable fibrous web structure.

BACKGROUND OF THE INVENTION

Many personal health care products in the market today are soldcontaining water. The water in the formula adds to the weight and sizeof the products and translates into greater shipping and storage costs.Additionally, these types of products also have disadvantages in termsof packaging, storage, transportation, and convenience of use. It canalso be difficult to control the dosing of liquid personal health careproducts. Moreover, the presence of water in personal health careproducts increases susceptibility to degradation of water unstableingredients and promotes negative interactions between two or moreincompatible materials in an article.

Some personal health care products are swallowable and sold as capsules,pills, caplets, and tablets and users need a drink, such as water, toconsume the product. It can be inconvenient for a user to find a drinkto consume a personal health care product in this form. Other personalhealth care products are chewable and sold as tablets. These chewabletablets do not require a drink for consumption. However, they are notdurable and tend to break when the user transports them and often have achalky flavor. Furthermore, pediatric and geriatric patients havedifficulty swallowing larger oral dosage forms.

Some personal health care products are available in a dissolvable strip.However, these strips have a low loading capacity which limits thevariety and amount of personal health care actives that can be added tothe dosage form. Furthermore, these strips and the processes for makingthe strips do not offer the flexibility and rates of production thatpersonal health care articles comprising one or more filaments offer.

Therefore, a need exists for personal health care articles that do notcontain a liquid, can be consumed by the user without a drink, aredurable during transport, and can contain broad ranges of health careactives and aesthetic agents, which includes higher levels of healthcare actives than are currently available in dissolvable strips. Thefilaments and personal health care articles of this invention can bedelivered to the user in need via the oral cavity, mouth, throat, nasalpassage, rectum, vagina, skin, eyes, ears and combinations thereof. Inone embodiment, the filaments and personal health care articles of thisinvention interact with the moisture in the oral cavity or mouth todisintegrate and release one or more health care actives that are thenconsumed by the user.

SUMMARY OF THE INVENTION

An oral care article comprising a nonwoven web comprising a plurality ofinterwoven filaments, the filaments comprise (a) from about 10% to about80%, by weight on a dry filament basis of one or more backbonematerials, (b) greater than 50% by weight on a dry filament basis, ofone or more oral care actives wherein said oral care actives are exposedto conditions of intended use, and (c) less than 10%, by weight of thefilament, moisture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic of a circular nozzle for forming filamentsaccording to fluid film fibrillation of the present invention;

FIG. 1B is an enlarged view of a portion of the circular nozzle forforming filaments of FIG. 1A;

FIG. 2A is a schematic of a slot nozzle for forming filaments accordingto fluid film fibrillation of the present invention;

FIG. 2B is an enlarged view of a portion of the slot nozzle for formingfilaments of FIG. 2A;

FIG. 3 is a schematic representation of an apparatus suitable for makinga filament according to meltblowing of the present invention; and

FIG. 4 is a schematic representation of a die suitable for forming afilament according to the meltblowing of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

An embodiment of the invention can be directed towards a method ofdelivering a health care active comprising the steps of: (a)administering to a mammal a personal health care article wherein saidpersonal health care article comprises a nonwoven web comprising afilament comprising (i) a backbone material; and (ii) a health careactive; and (b) said mammal consumes said article in its intendedmanner.

These and other limitations of the articles, process, and methods of thepresent invention, as well as many of the optional ingredients suitablefor use herein, are described in detail hereinafter.

As used herein, the term “filament” means a thin, flexible threadlikeobject that can be used to form a nonwoven web of the present type. Thelength of a filament can greatly exceed its diameter, i.e. a length todiameter ratio of at least about 10.

The filaments of the present invention may be spun from backbonematerials via suitable spinning operations, such as meltblowing orspunbonding.

Filaments are typically considered continuous or substantiallycontinuous in nature. Filaments are relatively longer than fibers (whichare less than 5.08 cm (2 in.) in length). Non-limiting examples offilaments can include meltblown filaments, spunbond filaments, andcombinations thereof. In one embodiment, the filaments are meltblownfilaments.

In one example, the filaments may be in the form of fibers, such as whenthe filaments are cut to shorter lengths (such as less than 5.08 cm inlength). Thus, in one example, the present invention also includes afiber comprising the composition of the filament of the presentinvention.

As used herein, “backbone material” means a composition that is suitablefor making a filament such as by meltblowing, spunbonding, or fluid filmfibrillation. The backbone material comprises one or more backbonematerials that exhibit properties that make them suitable for spinninginto a filament.

As used herein, “length”, with respect to a filament, means the lengthalong the longest axis of the filament from one terminus to the otherterminus. If a filament has a kink, curl or curves in it, then thelength is the length along the entire path of the filament.

As used herein, “average diameter”, with respect to a filament, ismeasured according to the Diameter Test Method described herein.

As used herein, the term “disintegratable” and “disintegration” meansthat the personal health care article, filament, or nonwoven is reducedto components, fragments or particles when exposed to conditions ofintended use. In one embodiment, the personal health care article,filament, or nonwoven web partially or completely dissolves. As usedherein, the term “dissolves” means that the personal health carearticle, filament, or nonwoven web is completely solubilized.

As used herein, the term “consumable” as used herein refers to personalhealth care articles in a form that is deliverable to a mammal in needvia the oral cavity including the lips, mouth, tongue, gums, teeth,gingival sulcus, and throat, nasal passages, rectum, vagina, skin (e.g.transdermal drug delivery system or other topical preparations), eyes,ears and combinations thereof.

As used herein “delayed delivery health care actives” refers to a healthcare active where the health care active is available to the user at atime later than immediately following its administration.

As used herein “extended delivery health care active” refers to a healthcare active wherein the benefit from the health care active isexperienced over time.

As used herein “immediate delivery health care active” refers to ahealth care active wherein the benefit from the health care active isexperienced soon after its administration.

As used herein “targeted delivery health care actives” refers to dosageforms wherein the dosage form is designed to provide the benefit fromthe health care active to the desired part of the body.

As used herein, the term “applying” includes spraying, dusting,sprinkling, coating, surface-printing (e.g., in the shape of a desiredadornment, decoration, or pattern), pouring on, injecting into theinterior, dipping, or by any other suitable means, such as by use of adepositor, sifter, or powder bed.

As used herein, “conditions of intended use” means the temperature,physical, chemical, and/or mechanical conditions that a personal healthcare article comprising one or more filaments of the present inventionis exposed to when the personal health care article is used for itsdesigned purpose. The personal health care articles of the presentinvention can be administered to a mammal via the oral cavity, mouth,throat, nasal passage, rectum, vagina, eye, ear, and combinationsthereof. In another embodiment, the personal health care article can beapplied to the skin. The conditions of intended use can be thetemperature, physical, chemical, and/or mechanical conditions in theoral cavity, mouth, throat, nasal passage, rectum, vagina, eye, ear, oron the skin of a mammal.

“Triggering condition” as used herein means anything, as an act or eventthat serves as a stimulus and initiates or precipitates a change in thefilament, such as a loss or altering of the filament's physicalstructure and/or a release a health care active.

“Morphology changes” as used herein with respect to a filament'smorphology changing means that the filament experiences a change in itsphysical structure. Non-limiting examples of morphology changes for afilament of the present invention include dissolution, melting,swelling, shrinking, breaking into pieces, lengthening, shortening,peeling, splitting, shredding, imploding, twisting, and combinationsthereof. The filaments of the present invention may completely orsubstantially lose their filament physical structure or they may havetheir morphology changed or they may retain or substantially retaintheir filament physical structure as they are exposed to conditions ofintended use.

As used herein, “by weight on a dry filament basis” means that thecontent is determined based on the “bone dry” weight as determined bythe Moisture Content Test Method described hereafter.

As used herein and as defined by European Disposables and NonwovensAssociation (EDANA), “nonwoven web” means a sheet of continuousfilaments of any nature or origin that have been formed into a web byany means, and bonded together by any means, with the exception ofweaving or knitting. Felts obtained by wet milling are not nonwovens. Inone example, a nonwoven web according to the present invention means anorderly arrangement of filaments within a structure in order to performa function. In one example, a nonwoven web of the present invention isan arrangement comprising a plurality of two or more and/or three ormore filaments that are inter-entangled or otherwise associated with oneanother to form a nonwoven web.

As used herein, the term “treat” or “treating” includes preventing,alleviating, ameliorating, inhibiting, or mitigating one or more healthconditions in a mammal. Non-limiting examples of health conditions caninclude respiratory conditions, gastrointestinal conditions, centralnervous system conditions, pathogenic infections, nutritionaldeficiencies, and combinations thereof. In one embodiment, the mammaltreated may be a human and in another embodiment that mammal can be acompanion animal such as a dog, cat or horse.

As used herein, the term “prevent”, “preventing” or “prevention”includes averting one or more health care conditions or its associatedsymptoms from occurring in a mammal, for example when the mammal ispredisposed to acquiring the symptoms of coughing, inhibiting the onsetof coughing or its associated symptoms; and/or alleviating, reversing,or curing the coughing episode or its associated symptoms.

As used herein, the term “orally administering” and/or “administering”with respect to the mammal means that the mammal consumes or is directedto consume (whether by swallowing or any other means) one or more of thepersonal health care articles. The mammal may be directed to deliver thepersonal health care article to the site that is intended to be treated,for example, the oral cavity. The mammal may be directed to consume thepersonal health care article, and such direction and or delivery may bethat which instructs and/or informs the mammal that use of the personalhealth care article may provide a wellness benefit. The benefit can beinstant, delayed or extended. For example, such direction may be oraldirection (e.g., through a diagnosis followed by oral instruction from,for example, a physician, pharmacist, veterinarian, or other healthprofessional), radio or television media (e.g., advertisement), orwritten direction (e.g., through a diagnosis followed by writtendirection from, for example, a physician, pharmacist, veterinarian, orother health professional (e.g., scripts), sales professionalorganization (e.g., through, for example, marketing brochures,pamphlets, or other instructive paraphernalia), written media (e.g.,internet, electronic mail, or other computer-related media)), and/orpackaging associated with the personal health care article (e.g., alabel present on a delivery device holding the personal health carearticle). As used herein, “written” means through words, pictures,symbols, and/or other visible or tactile descriptors. Such informationneed not utilize the actual words used herein, for example,“respiratory”, “symptom”, or “mammal”, but rather use of words,pictures, symbols, tactile means, and the like conveying the same orsimilar meaning are contemplated within the scope of this invention.

Health care actives and aesthetic agents useful herein may becategorized or described herein by their health benefit and/or healthconditions or their postulated mode of action or function. However, itis to be understood that the health care actives and aesthetic agentsuseful herein can, in some instances, provide more than one healthbenefit and/or health conditions or function or operate via more thanone mode of action. Therefore, classifications herein are made for thesake of convenience and are not intended to limit an ingredient to theparticularly stated function(s) or activities listed.

As used herein, the articles “a” and “an” is understood to mean one ormore of the material that is claimed or described, for example, “anaesthetic agent” or “a filament”.

All weights, measurements and concentrations herein are measured at 23degrees Celsius (° C.) and 50% relative humidity on the personal healthcare article, unless otherwise specified.

All percentages, parts and ratios as used herein are by weight of thetotal personal health care article, unless otherwise specified. All suchweights as they pertain to listed ingredients are based on the activelevel and, therefore do not include solvents or by-products that may beincluded in commercially available materials, unless otherwisespecified.

The article, process and methods of the present invention can comprise,consist of, or consist essentially of, the essential elements andlimitations of the invention described herein, as well as any additionalor optional ingredients, components, or limitations described herein orotherwise useful in personal health care articles intended for use orconsumption by mammals preferably consumption or use by humans.

Personal Health Care Article

The personal health care article can comprise one or more filaments. Thepersonal health care article can be administered directly to a mammal orincorporated into a device. The use of such a personal health carearticle allows for easy portability and the ability to better controldosing. Once disintegrated or dissolved, the personal health carearticle can be consumed by to the user.

The personal health care article can also be delivered via a waterinsoluble implement or device. For instance, the personal health carearticle may be attached or glued by some mechanism to an applicator tofacilitate application to the oral cavity, mouth, throat, nasal passage,rectum, vagina, skin i.e., a comb, rag, wand, or any other conceivablewater-insoluble applicator. In an embodiment, the personal health carearticle is placed into a liquid, such as water, disintegrated and thenadministered to the mammal. In another embodiment, the personal healthcare article is a suppository.

In an embodiment, the personal health care article of the presentinvention has a basis weight of from about 20 grams per square meter(g/m²) to about 1000 g/m², in yet another embodiment from about 25 g/m²to about 500 g/m², in a further embodiment from about 40 g/m² to about250 g/m², and in another embodiment from about 50 g/m² to about 100g/m².

In an embodiment, the personal health care article of the presentinvention can be a flat article in the form of a pad, strip, tape, ortablet having a thickness of from about 0.05 millimeter (mm) to about 20mm, in another embodiment from about 0.05 mm to about 10 mm, in yetanother embodiment from about 0.05 mm to about 5 mm, in a furtherembodiment from about 0.5 mm to about 1 mm, in another embodiment fromabout 0.05 mm to about 0.5 mm, in yet another embodiment from about 0.05mm to about 0.25 mm, and in another embodiment from about 0.05 mm toabout 0.1 mm, as measured by the Thickness Method described hereafter.In another embodiment, the personal health care article can be formedinto a cylindrical shape (e.g. by rolling) having a length from about0.5 centimeter (cm) to about 10 cm, in another embodiment from about 1cm to about 5 cm, and in another embodiment from about 1.5 cm to about 3cm. In another embodiment the personal health care article can be arectangular prism including a cube wherein the longest sides of therectangular prism has a length from about 5 mm to 20 mm, in anotherembodiment from about 10 mm to 15 mm, and in a further embodiment fromabout 5 mm to about 10 mm, as measured by the Thickness Method describedhereafter.

In an embodiment, the personal health care article is in the form of oneor more flat sheets or pads of an adequate size to be able to be handledeasily by the user. In another embodiment, the flat sheet or padcontains one unit dose of one or more health care actives that canprovide one or more health benefits and/or treat one or more healthconditions. The personal health care article may have a square,rectangle or disc shape or any other suitable shape. The personal healthcare article can also be in the form of a continuous strip includingdelivery on a tape-like roll dispenser with individual portionsdispensed via perforations and/or a cutting mechanism.

In one embodiment, the personal health care articles of the presentinvention can be formed by one or more nonwoven webs. The nonwoven webcan be formed by one or more filaments. In another embodiment, thepersonal health care article may comprise two or more layers wherein atleast one of the layers comprises a nonwoven web. In another embodiment,the personal health care article comprises two or more layers whereineach of the layers comprises a nonwoven web. In another embodiment, thepersonal health care article comprises a first nonwoven web and a secondnonwoven web wherein the first nonwoven web comprises a health careactive and the second nonwoven web comprises an aesthetic agent.

In an embodiment, the nonwoven web contains more than one filament. Inanother embodiment, the nonwoven web comprises a first filament and asecond filament both comprising a health care active and the health careactive can be the same health care active or different health careactives. In another embodiment, the nonwoven web comprises a firstfilament comprising an immediate delivery health care active and asecond filament comprising an extended delivery, a delayed delivery,and/or a targeted delivery health care active. In another embodiment,the nonwoven web comprises a first filament and a second filamentwherein the first filament comprises one or more health care actives andthe second filament comprises one or more aesthetic agents. In anotherembodiment, the nonwoven web comprises a first filament, a secondfilament, and a third filament, wherein each filament comprises adifferent health care active.

In an embodiment, the nonwoven web or personal health care articlecomprises a plurality of identical or substantially identical, from acompositional perspective, filaments according to the present invention.In another embodiment, the nonwoven web or personal health care articlemay comprise two or more different filaments according to the presentinvention. Non-limiting examples of differences in the filaments may bephysical differences such as differences in diameter, length, texture,shape, rigidness, elasticity, and the like; chemical differences such ascrosslinking level, solubility, melting point, glass transitiontemperature (Tg), backbone material, color, amount of health careactive, amount of backbone material, presence of a coating compositionon the filament, chemical composition of the health care activeincluding whether the health care active is immediate delivery, delayeddelivery, extended delivery, or targeted delivery, and the like;differences in whether the filament loses its physical structure whenthe filament is exposed to conditions of intended use; differences inwhether the filament's morphology changes when the filament is exposedto conditions of intended use; and differences in when and where thebenefit from the health care active is experienced. In one example, twoor more filaments within the personal health care article or nonwovenweb may comprise the same backbone material, but have different healthcare actives.

In an embodiment, the personal health care article or nonwoven webcomprises two or more filaments wherein the filaments release the healthcare actives at different rates. The different rates may be caused bythe filaments being positioned at an external surface of the nonwovenweb.

In an embodiment, the personal health care article or nonwoven webcomprises two or more active agents that are generally consideredincompatible with one another in a liquid formulation, for examplesimethicone and calcium carbonate. Health care actives are incompatiblewith one another, if when they are in the same composition, at least oneof the health care actives has a significant reduction in efficacy,stability, or bioavailability.

In another embodiment, the personal health care article or nonwoven webmay exhibit different regions, such as different regions of basisweight, density and/or caliper. In an embodiment, the personal healthcare article or nonwoven web may comprise discrete regions of filamentsthat differ from other parts of the nonwoven web.

The personal health care article or the nonwoven web may comprise one ormore textured, dimpled or otherwise topographically patterned surfacesincluding letters, logos or figures. The textured personal health carearticle can result from the shape of the filament or the nonwoven web,in that the outermost surface of the article contains portions that areraised with respect to other areas of the surface. The raised portionscan result from the formed shape of the personal health care article,for example the nonwoven web can be formed in a dimpled or wafflepattern. The raised portions can also be the result of crepingprocesses, imprinted coatings, embossing patterns, or the result of thephysical form of the article itself.

In an embodiment, the nonwoven web of the present invention may bepressed into a film to form the personal health care article; this canbe done by applying a compressive force and/or heating the nonwoven webto convert the nonwoven web into a film. The film would comprise thehealth care actives that were present in the filaments of the presentinvention. The nonwoven web may be completely converted into a film orparts of the nonwoven web may remain in the form of a film after partialconversion of the nonwoven web into the film. In yet another embodiment,the personal health care article may constitute one or more nonwovenwebs wherein at least one of the nonwoven webs has been pressed into afilm. In another embodiment, the personal health care article comprisestwo or more nonwoven webs that have been pressed into a film.

In another embodiment, the nonwoven web can be rolled, compressed, cut,or stacked to form a three dimensional personal health care article. Forinstance, the nonwoven web may be compressed into a pill or tablet,rolled into a cylinder, or compressed or stacked into a rectangularprism to form the personal health care article.

In another embodiment, the personal health care article may constituteone or more layers of nonwoven webs which are optionally bonded togethervia a bonding means (including heat, moisture, ultrasonic, pressureetc.).

Product Types

Non-limiting examples of product type embodiments for use by the Articleand methods of the present invention include personal care articles,oral care articles, personal health care articles, household carearticles, and other cleaning articles. Non-limiting examples of oralcare articles include teeth cleaning articles, teeth whitening articles,tooth care articles, periodontal gum care articles, denture cleaningarticles, tongue cleaning articles, breath freshening articles, fluoridecontaining articles, mouth rinse articles, anti-cavity articles, andcombinations thereof.

In another embodiment, the personal health care article or nonwoven webcan be perforated with holes or channels penetrating into or through thepersonal health care article or nonwoven web. These perforations can beformed as part of making the nonwoven web or personal health carearticle via spikes extended from the surface of an adjacent belt, drum,roller or other surface. Alternatively, these perforations can be formedafter forming the nonwoven web or personal health care article by aprocess of poking or sticking the porous solids with pins, needles orother sharp objects.

Filament

The personal health care article can comprise one or more filaments. Inan embodiment, the filaments of the present invention exhibit a lengthof greater than about 5.08 cm (2 in.), in an alternate embodimentgreater than about 7.62 cm (3 in.), in still another embodiment greaterthan about 10.16 cm (4 in.), and in another embodiment greater thanabout 15.24 cm (6 in.).

In one embodiment, the filaments can have an average diameter of lessthan about 150 micrometers (μm), in another embodiment less than about100 μm, in an another embodiment less than about 10 μm, and in an yetanother embodiment less than about 1 μm with a relative standarddeviation of less than 100%, alternatively less than 80%, alternativelyless than 60%, alternatively less than 50%, such as in the range of 10%to 50%, for example. As set forth herein, the significant number meansat least 10% of all the filaments, in another embodiment at least 25% ofall the filaments, in another embodiment at least 50% of all thefilaments, in yet another embodiment at least 75% of all the filaments.In a particular embodiment, the significant number may be at least 99%of all the filaments. In a further embodiment, at least 50% of all thefilaments may have an average diameter less than about 10 μm. Thefilaments produced by the method of the present disclosure have asignificant number of filaments with an average diameter less than about1 μm, or sub-micron filaments. In an embodiment, the personal healthcare article can comprise at least 25% of all the filaments with anaverage diameter less than about 1 μm, in another embodiment at least35% of all the filaments with an average diameter less than about 1 μm,in another embodiment at least 50% of all the filaments with an averagediameter less than about 1 μm, and in yet another embodiment at least75% of all the filaments with an average diameter less than about 1 μm.

In one embodiment, the filament can comprise less than 20% moisture, byweight of the filament, in another embodiment less than about 15%moisture, by weight of the filament, in another embodiment less thanabout 10% moisture, by weight of the filament, in another embodimentless than about 7%, by weight of the filament, in yet another embodimentless than about 5%, and in another embodiment less than about 3%, byweight of the filament, as measured by the Moisture Content Test Method,described hereafter.

The filament of the present invention can be monocomponent ormulticomponent. In one embodiment, the filament is a bicomponentfilament. In another embodiment, the filament is a tricomponentfilament. The multicomponent filament may be in any form, such asside-by-side, core and sheath, islands-in-the-sea and the like.

In one embodiment, the filaments of the present invention may bemeltblown filaments. In another example, the filaments of the presentinvention may be spunbond filaments. In another example, the filamentsmay be hollow filaments prior to and/or after release of one or more ofits active agents.

In one embodiment, the filament may comprise a health care active withinthe filament and a health care active on an external surface of thefilament, such as a coating on the filament. The health care active onthe external surface of the filament may be the same or different fromthe active agent present in the filament. If different, the health careactives may be compatible or incompatible with one another.

In one embodiment, the filaments may be applied to and/or deposited on acarrier substrate, for example a wipe, paper towel, bath tissue, facialtissue, sanitary napkin, tampon, diaper, adult incontinence article,washcloth, bandage, and the like.

Health Care Active

The filament may comprise one or more health care actives. In anembodiment, one or more health care actives may be uniformly distributedor substantially uniformly distributed throughout the filament. Inanother embodiment, one or more health care actives may be distributedas discrete regions within the filament. In still another embodiment, atleast one health care active is distributed uniformly or substantiallyuniformly throughout the filament and at least another health careactive is distributed as one or more discrete regions within thefilament. In still yet another embodiment, at least one health careactive is distributed as one or more discrete regions within thefilament and at least another health care active is distributed as oneor more discrete regions different from the first discrete regionswithin the filament.

The one or more health care actives can include respiratory agents,gastrointestinal agents, central nervous system (CNS) agents,anti-infective agents, nutritional agents, overall wellbeing agents andcombinations thereof. The one or more health care actives of the presentinvention can also be selected from the group consisting of delayeddelivery health care actives, extended delivery health care actives,immediate delivery health care actives, targeted delivery health careactives, and combinations thereof. In an embodiment, one or more healthcare actives are encapsulated. In one embodiment the health care activeis selected from the group consisting of dextromethorphan, fexofenadine,famotidine, naproxen, vitamin B₉, and combinations thereof.

The personal health care articles of the present invention may alsotreat one or more health conditions. Non-limiting examples of healthconditions can include respiratory conditions, gastrointestinalconditions, CNS conditions, pathogenic infections, nutritionaldeficiencies, and combinations thereof.

The personal health care articles of the present invention may alsoprovide one or more health benefits. Non-limiting examples of healthbenefits can include respiratory benefits, gastrointestinal benefits,CNS benefits, anti-infection benefits, nutritional benefits, overallwellbeing benefits, and combinations thereof.

In one embodiment, the health care actives comprise particles. Theparticles of the health care article are less than about 1 μm, inanother embodiment the particles are less than about 750 nanometers(nm), in a different embodiment less than about 500 nm, in yet anotherembodiment less than about 250 nm, in another embodiment less than about100 nm, in yet another embodiment less than about 50 nm, in anotherembodiment less than about 25 nm, in another embodiment less than about10 nm, in another embodiment less than about 5 nm, and in yet anotherembodiment less than about 1 nm.

All health care actives may be present from about 10% to about 90%, byweight on a dry filament basis, in another embodiment from about 15% toabout 80%, by weight on a dry filament basis, in a different embodimentfrom about 20% to about 75%, by weight on a dry filament basis, inanother embodiment from about 25% to about 70%, by weight on a dryfilament basis, in a different embodiment from about 30% to about 60%,by weight on a dry filament basis, and in another embodiment from about35% to about 60%, by weight on a dry filament basis. In anotherembodiment, the filament comprises greater than about 10%, by weight ona dry filament basis, health care actives, in yet another embodimentgreater than about 15%, by weight on a dry filament basis, health careactives, in another embodiment, greater than about 25%, by weight on adry filament basis, health care actives, in still another embodimentgreater than about 35%, by weight on a dry filament basis, health careactives, in another embodiment greater than about 40%, by weight on adry filament basis, health care actives, in another embodiment greaterthan about 45%, by weight on a dry filament basis, health care actives,an in yet another embodiment greater than about 50%, by weight on a dryfilament basis, health care actives.

Respiratory Agents

In an embodiment one or more health care actives can be a respiratoryagent. Non-limiting examples of respiratory agents can include nasaldecongestants, mucolytics, expectorants, antihistamines, antitussives,demulcents, anesthetics, plant-derived respiratory agents, andcombinations thereof. Respiratory agents may be used to treatrespiratory conditions. Non-limiting examples of respiratory conditionscan include influenza, the common cold, pneumonia, bronchitis, and otherviral infections; pneumonia, bronchitis, and other bacterial infections;allergies; sinusitis; rhinitis; and combinations thereof. Respiratoryagents may provide a respiratory benefit. Non-limiting examples ofrespiratory benefits can include treating, respiratory symptoms.Non-limiting examples of respiratory symptoms include nasal congestion,chest congestion, rhinorrhea, coughing, sneezing, headache, malaise,sore throat, difficulty breathing, sinus pressure, sinus pain, andcombinations thereof.

Non-limiting examples of decongestants can include phenylephrine,1-desoxyephedrine, ephedrine, propylhexedrine, pseudoephedrine,phenylpropanolamine, and combinations thereof. Decongestants can bepresent in the filament from about 0.5% to about 40%, by weight on a dryfilament basis, alternatively from about 1% to about 30%, by weight on adry filament basis, and alternatively from about 5% to about 20%, byweight on a dry filament basis.

Non-limiting mucolytics can include ambroxol, bromhexine,N-acetylcysteine, and combinations thereof. Mucolytics can be present inthe filament from about 0.5% to about 40%, by weight on a dry filamentbasis, alternatively from about 1% to about 50%, by weight on a dryfilament basis, and alternatively from about 10% to about 60%, by weighton a dry filament basis.

Non-limiting expectorants can include guaifenesin, terpin hydrate, andcombinations thereof. Expectorants can be present in the filament fromabout 1% to about 40%, by weight on a dry filament basis, alternativelyfrom about 2% to about 50%, by weight on a dry filament basis, andalternatively from about 10% to about 60%, by weight on a dry filamentbasis.

Non-limiting examples of antihistamines can include chlorpheniramine,diphenhydramine, triprolidine, clemastine, pheniramine, brompheniramine,dexbrompheniramine, loratadine, cetirizine and fexofenadine, amlexanox,alkylamine derivatives, cromolyn, acrivastine, ibudilast, bamipine,ketotifen, nedocromil, omalizumab, dimethindene, oxatomide, pemirolast,pyrrobutamine, pentigetide, thenaldine, picumast, tolpropamine,ramatroban, repirinast, suplatast tosylate aminoalkylethers, tazanolast,bromodiphenhydramine, tranilast, carbinoxamine, traxanox,chlorphenoxamine, diphenylpyaline, embramine, p-methyldiphenhydramine,moxastine, orphenadrine, phenyltoloxamine, setastine, ethylenediaminederivatives, chloropyramine, chlorothen, methapyrilene, pyrilamine,talastine, thenyldiamine, thonzylamine hydrochloride, tripelennamine,chlorcyclizine, clocinizine, homochlorcyclizine, hydroxyzine,tricyclics, phenothiazines, mequitazine, promethazine, thiazinamiummethylsulfate, azatadine, cyproheptadine, deptropine, desloratadine,isothipendyl, olopatadine, rupatadine, antazoline, astemizole,azelastine, bepotastine, clemizole, ebastine, emedastine, epinastine,levocabastine, mebhydroline, mizolastine, phenindamine, terfenadine,tritoqualine, and combinations thereof. In one embodiment, the healthcare active can be fexofenadine. Antihistamines can be present in thefilament from about 0.5% to about 30%, by weight on a dry filamentbasis, alternatively from about 1% to about 20%, by weight on a dryfilament basis, alternatively from about 5% to about 15%, by weight on adry filament basis.

Non-limiting examples of antitussives can include benzonatate,chlophedianol, dextromethorphan, levodropropizine, and combinationsthereof. In one embodiment the health care active can bedextromethorphan. Antitussives can be present in the filament from about0.5% to about 30%, by weight on a dry filament basis, alternatively fromabout 1% to about 20%, by weight on a dry filament basis, andalternatively from about 5% to about 15%.

Non-limiting examples of demulcents can include glycerin, honey, pectin,gelatin, liquid sugar, and combinations thereof. Demulcents can bepresent in the filament from about 1% to about 60%, by weight on a dryfilament basis, alternatively from about 5% to about 50%, by weight on adry filament basis, and alternatively from about 10% to about 40%, byweight on a dry filament basis.

Non-limiting examples of anesthetics can include menthol, phenol,benzocaine, lidocaine, hexylresorcinol, and combinations thereof.Anesthetics can be present in the filament from about 0.5% to about 40%,by weight on a dry filament basis, alternatively from about 1% to about30%, by weight on a dry filament basis, and alternatively from about 5%to about 20%, by weight on a dry filament basis. In certain embodiments,the anesthetics can be present in the filament from about 0.5% to about20%, and in another embodiment from about 0.5% to about 10%.

Non-limiting examples of plant-derived respiratory agents can includeandrographis (Andrographis paniculata), garlic (Allium sativum L.),Eleutherococcus senticosus, a guaiacol component (from oils of cassia(Cinnamomum aromaticum), clove (Syzygium aromaticum, Eugenia aromaticum,Eugenia caryophyllata), or cinnamon (Cinnamomum zeylanicum, Cinnamomumverum, Cinnamomum loureiroi, Cinnamomum camphora, Cinnamomum tamala,Cinnamomum burmannii)), borage seed oil (Borago officinalis), sage(Salvia officinalis, Salvia lavandulaefolia, Salvia lavandulifolia),astragalus (Astragalus membraneceus), boneset (Eupatorium perfoliatum),chamomile (Matricaria recutita, Chamaemelum nobile), cordyceps(Cordyceps sinensis), echinacea (Echinacea angustifolia DC, Echinaceapallida, Echinacea purpurea), elder (Sambucas nigra L.), euphorbia,ginseng (American ginseng, Asian ginseng, Chinese ginseng, Korean redginseng, Panax ginseng: Panax ssp. Including P. ginseng C.C. Meyer, andP. quinquefolius L.), goldenseal (Hydrastis canadensis L.), greatercelandine (Chelidonium majus), horseradish (Armoracia rusticana,Cochlearia armoracia), maitake mushrooms (Grifola frondosa) mistletoe(Visvum album L.), geranium (Pelargonium sidoides),peppermint/peppermint oil (Mentha x peperita L.), propolis, slippery elm(Ulmus rubra Muhl, Ulmus fulva Michx), Sorrel (Rumex acetosa L., Rumexacetosella L.), thyme/thymus extract (Thymus vulgaris L.), wild indigo(Baptisia australis), quercetin (a flavanol), and combinations thereof.Plant derived respiratory agents can be present in the filament fromabout 0.5% to about 50%, by weight on a dry filament basis,alternatively from about 1% to about 40%, by weight on a dry filamentbasis, and alternatively from about 10% to about 30%, by weight on a dryfilament basis.

Gastrointestinal Agents

In an embodiment the one or more health care actives can be agastrointestinal agent. Non-limiting examples of gastrointestinal agentscan include anti-diarrheals, lower gastrointestinal agents, laxatives,anti-emetics, antacids, anti-flattulents, H₂ receptor antagonists,proton pump inhibitors, lipase inhibitors, rafting agents, probiotics,prebiotics, dietary fiber, enzymes, plant-derived gastrointestinalagents, anesthetics, and combinations thereof. Gastrointestinal agentsmay be used to treat gastrointestinal conditions. Non-limiting examplesof gastrointestinal conditions can include, gastroesophageal refluxdisease, gastritis, peptic ulcers, dyspepsia, irritable bowel syndrome,colitis, Crohn's disease, Barrett's esophagus, gastrinoma, diarrhea,indigestion, constipation, obesity, pouchitis, diverticulitis,enteritis, enterocolitis, dysphagia, inflamed hemorrhoids, foodpoisoning and other bacterial infections, influenza and other viralinfections, and combinations thereof. Gastrointestinal agents mayprovide gastrointestinal benefits. Non-limiting examples ofgastrointestinal benefits can include restoring digestive balance,treating gastrointestinal symptoms, and combinations thereof.Non-limiting examples of gastrointestinal symptoms can include diarrhea,constipation, upset stomach, vomiting, sour stomach, cramps, gas,bloating, stomach ache, lactose intolerances, sore throat, difficultyswallowing, unintentional weight loss, visceral hypersensitivity,feeling of fullness, indigestion, nausea, heartburn, urgency to have abowel movement, lack of appetite, regurgitation, belching, flatulence,blood in stool, dehydration, and combinations thereof.

Non-limiting examples of anti-diarrheals can include loperamide,pharmaceutically acceptable salts of bismuth, attapulgite, activatedcharcoal, bentonite, and combinations thereof. The anti-diarrheals canbe present in the filament from about 0.25% to about 60%, by weight on adry filament basis, alternatively from about 0.1% to about 50%, byweight on a dry filament basis, and alternatively from about 5% to about40%, by weight on a dry filament basis.

Non-limiting examples of lower gastrointestingal agents can includemesalamine, olsalazine sodium, balsalazide disodium, sulfasalazine,tegaserod maleate, and combinations thereof. Lower gastrointestinalagents can be present in the filament from about 0.5% to about 60%, byweight on a dry filament basis, alternatively from about 1% to about50%, by weight on a dry filament basis, and alternatively from about 5%to about 40%, by weight on a dry filament basis.

Non-limiting examples of laxatives can include bisacodyl, cascarasagrada, castor oil, dietary fiber, resistant starch, resistantmaltodextrin, docusate calcium, docusate sodium, lactulose, sennosides,mineral oil, polyethylene glycol 400, polyethylene glycol 3350, andcombinations thereof. The laxatives can be present in the filament fromabout 0.5% to about 85%, by weight on a dry filament basis,alternatively from about 0.1% to about 50%, by weight on a dry filamentbasis, and alternatively from about 5% to about 40%, by weight on a dryfilament basis.

Non-limiting examples of anti-emetics can include cyclizine, meclizine,buclizine, dimenhydrinate, scopolamine, trimethobenzamide, dronabinol,5-HT₃ receptor antagonists, aprepitant, and combinations thereof.Anti-emetics can be present in the filament from about 0.5% to about50%, by weight on a dry filament basis, alternatively from about 1% toabout 40%, by weight on a dry filament basis, and alternatively fromabout 5% to about 30%, by weight on a dry filament basis.

Non-limiting examples of antacids can include sodium bicarbonate, sodiumcarbonate, calcium carbonate, magnesium carbonate, magnesium hydroxide,aluminum hydroxide, magaldrate, and combinations thereof. The antacidscan be present in the filament from about 10% to about 60%, by weight ona dry filament basis, alternatively from about 25% to about 50%, byweight on a dry filament basis, and alternatively from about 35% toabout 45%, by weight on a dry filament basis.

Non-limiting examples of anti-flatulents can include simethicone. Theanti-flatulents can be present in the filament from about 0.5% to about50%, by weight on a dry filament basis, alternatively from about 1% toabout 40%, by weight on a dry filament basis, and alternatively fromabout 5% to about 30%, by weight on a dry filament basis.

Non-limiting examples of H₂ receptor antagonists can include famotidine,ranitidine, cimetidine, nizatidine, and combinations thereof. In oneembodiment, the health care active can be famotidine. The H₂ receptorantagonists can be present in the filament from about 0.5% to about 50%,by weight on a dry filament basis, alternatively from about 1% to about40%, by weight on a dry filament basis, and alternatively from about 2%to about 30%, by weight on a dry filament basis.

Non-limiting examples of proton pump inhibitors can include omeprazole,lansoprazole, esomeprazole, pantoprazole, rabeprazole, and combinationsthereof. The proton pump inhibitors can be present in the filament fromabout 0.5% to about 40%, by weight on a dry filament basis,alternatively from about 0.5% to about 20%, by weight on a dry filamentbasis, alternatively from about 0.5% to about 10%, by weight on a dryfilament basis, and in yet another embodiment from about 0.5% to about5%, by weight on a dry filament basis.

Non-limiting examples of lipase inhibitors can include orlistat. Thelipase inhibitor can be present in the filament from about 0.5% to about40%, by weight on a dry filament basis, alternatively from about 1% toabout 35%, by weight on a dry filament basis, and alternatively fromabout 2% to about 30%, by weight on a dry filament basis.

The filament of the present invention may comprise rafting agents.Non-limiting examples of rafting agents can include alginates,fenugreek, guar gum, xanthan gum, carrageenan, and combinations thereof.The rafting agent can be present in the filament from about 1% to about60%, by weight on a dry filament basis, alternatively from about 5% toabout 50%, by weight on a dry filament basis, and alternatively fromabout 10% to about 40%, by weight on a dry filament basis.

The filament of the present invention may comprise probiotics.Non-limiting examples of probiotics can include microogranisms of thegenera Bacillus, Bacteroides, Bifidobacterium, Enterococcus (e.g.,Enterococcus faecium), Lactobacillus, Leuconostoc, Saccharomyces, andcombinations thereof. In another embodiment of the invention, theprobiotic is selected from bacteria of the genera Bifidobacterium,Lactobacillus, and combinations thereof.

Non-limiting examples of microorganisms can include strains ofStreptococcus lactis, Streptococcus cremoris, Streptococcusdiacetylactis, Streptococcus thermophilus, Lactobacillus bulgaricus,Lactobacillus acidophilus (e.g., Lactobacillus acidophilus strain),Lactobacillus helveticus, Lactobacillus bifidus, Lactobacillus casei,Lactobacillus lactis, Lactobacillus plantarum, Lactobacillus rhamnosus,Lactobacillus delbruekii, Lactobacillus thermophilus, Lactobacillusfermentii, Lactobacillus salivarius, Lactobacillus reuteri,Bifidobacterium longum, Bifidobacterium infantis, Bifidobacteriumbifidum, Bifidobacterium animalis, Bifidobacterium pseudolongum,Saccharomyces boulardii, Pediococcus cerevisiae, Lactobacillussalivarius, Bacillus coagulans, and combinations thereof. Probiotics canbe present in the filament from about 0.025% to about 10%, by weight ona dry filament basis, alternatively from about 0.025% to about 5%, byweight on a dry filament basis, alternatively from about 0.025% to about3%, by weight on a dry filament basis, and in yet another embodimentfrom about 0.025% to about 1%, by weight on a dry filament basis.

Non-limiting examples of prebiotics can include carob bean, citruspectin, rice bran, locust bean, fructooligosaccharide, oligofructose,galactooligosaccharide, citrus pulp, mannanoligosaccharides,arabinogalactan, lactosucrose, glucomannan, polydextrose, apple pomace,tomato pomace, carrot pomace, cassia gum, gum karaya, gum talha, gumarabic, and combinations thereof. Prebiotics can be present in thefilament from about 1% to about 85%, by weight on a dry filament basis,alternatively from about 10% to about 60%, by weight on a dry filamentbasis, and alternatively from about 20% to about 50%, by weight on a dryfilament basis.

Non-limiting examples of dietary fibers can include, but are not limitedto inulin, agar, beta-glucans, chitins, dextrins, lignin, cellulose,modified cellulose, cellulose ethers, hemicelluloses, non-starchpolysaccharides, reduced starch, polycarbophil, partially hydrolyzedguar gum, wheat dextrin, and combinations thereof.

In an embodiment, the dietary fiber comprises glucose polymers,preferably those which have branched chains. Among such suitable dietaryfibers is one marketed under the tradename “Fibersol2”, commerciallyavailable from Matsutani Chemical Industry Co., Itami City, Hyogo,Japan.

Other non-limiting examples of suitable dietary fibers can includeoligosaccharides, such as inulin and its hydrolysis products commonlyknown as fructooligosaccharides, galacto-oligosaccharides,xylo-oligosaccharides, oligo derivatives of starch, and combinationsthereof.

The dietary fiber can be provided in any suitable form. A non-limitingexample is in the form of a plant material which contains the dietaryfiber. Non-limiting examples of suitable plant materials can includeasparagus, artichoke, onion, wheat, chicory, beet pulp, residues ofthese plant materials, and combinations thereof.

A non-limiting example of a dietary fiber from such a plant material isinulin extract from extract of chicory. Suitable inulin extracts can beobtained from Orafti SA of Belgium under the trademark Raftiline®.Alternatively the dietary fiber can be in the form of afructo-oligosaccharide which can be obtained from Orafti SA of Belgiumunder the trademark Raftilose®. Alternatively, an oliogo-saccharide canbe obtained by hydrolyzing inulin, by enzymatic methods, or by usingmicroorganisms as will be understood by those of skill in the art.Alternatively the dietary fiber can be inulin and/or de-sugared inulinavailable from Cargill Health & Food Technologies, Wayzata, Minn., USA,or from Cosucra SA, Warcoing, Belgium.

In another embodiment, the dietary fiber can be psyllium, available,which can be obtained from The Procter & Gamble Company, Cincinnati,Ohio, under the trademark Metamucil®.

The filament of the present invention can comprise enzymes which caninclude purified enzymes, partially purified enzymes, extractscontaining enzymes, and combinations thereof. Enzymes can be producedsynthetically, through genetic modification, or they can be producednaturally by plants, animals, or microorganisms. In some embodiments theenzymes are produced by plants such as peppermint, pineapple, or papaya.In other embodiments the enzymes are produced by fungi such asAspergillus, Candida, Saccharomyces, and Rhizopus. In another embodimentthe enzymes are produced by an animal such as a pig or bovine. Incertain embodiments, the enzymes help support a more complete digestionof food for gastrointestinal health, regularity, and normal bowelfunction. In other embodiments, the enzymes can provide wellnessbenefits or health benefits.

Fiber can be present in the filament from about 1% to about 85%, byweight on a dry filament basis, alternatively from about 10% to about60%, by weight on a dry filament basis, and alternatively from about 20%to about 50%, by weight on a dry filament basis.

Non-limiting examples of enzymes can include, but are not limited to,proteases, amylases, lipases, and combinations thereof.

Other non-limiting examples of enzymes can include bromelain, pepsin,papain, amyloglucosidase, glucoamylase, malt diastase, maltase, lactase,α-galactosidase, β-glucanase, cellusase, hemilase, hemicellulase,cellulase, xylanase, invertase, pectinase, pancreatin, rennet, phytase,pancrelipase, and combinations thereof. Enzymes can be present in thefilament from about 0.5% to about 85%, by weight on a dry filamentbasis, alternatively from about 5% to about 70%, by weight on a dryfilament basis, and alternatively from about 10% to about 50%, by weighton a dry filament basis. In certain embodiments, enzymes can be presentin the filament from about 0.5% to about 70%, by weight on a dryfilament basis, in another embodiment from about 0.5% to about 50%, byweight on a dry filament basis, in a different embodiment from about0.5% to about 10%, by weight on a dry filament basis.

Non-limiting examples of plant-derived gastrointestinal agents caninclude materials from the Ginger family (Zigiberaceae), licorice root(Glycyrrhizin glabra), marshmallow root (Althea officinalis, Althearadix), fennel oil, fennel seed (Foeniculum vulgare), caraway oil,caraway seed (Carum carvi, Carvi fructus, Carvi aetheroleum), lemon balm(Melissae folium, Melissa), horehound herb (Murrubii herba), andflaxseed alpha-linoleic acid (Lini semen). Plant derivedgastrointestinal agents can be present in the filament from about 0.5%to about 50%, by weight on a dry filament basis, alternatively fromabout 1% to about 40%, by weight on a dry filament basis, andalternatively from about 10% to about 30%, by weight on a dry filamentbasis.

Central Nervous System Agents

In an embodiment the one or more health care actives can be a centralnervous system (CNS) agent. Non-limiting examples of CNS agents caninclude sleep aids, nonsteroidal anti-inflammatory drugs, salicylates,opioid analgesics, miscellaneous central nervous system stimulants,anti-emetics, and combinations thereof. Anti-emetics are describedherein. CNS agents may be used to treat CNS conditions. Non-limitingexamples of CNS conditions can include insomnia, restless leg syndrome,narcolepsy, pain, tobacco dependence, depression, attention deficitdisorder, attention deficit hyperactivity disorder, and combinationsthereof. Non-limiting examples of pain can include headaches, migraines,arthritis, post-operative pain, dental pain, and combinations thereof.CNS agents may provide CNS benefits. Non-limiting examples of CNSbenefits can include increasing alertness, restoring normal circadianrhythm, treating CNS symptoms, and combinations thereof. Non-limitingexamples of CNS symptoms can include insomnia, abnormal circadianrhythm, pain, fatigue, drowsiness, difficulty concentrating, irritation,vomiting, nausea, and combinations thereof.

The filament of the present invention can comprise sleep aids.Non-limiting examples of sleep aids can include aolpidem, eszopiclone,zaleplon, doxepin, doxylamine, melatonin, ramelteon, estazolam,flurazepam hydrochloride, quazepam, temazepam, triazolam, andcombinations thereof. In certain embodiments, sleep aids can be presentin the filament from about 10% to about 60%, by weight on a dry filamentbasis, in another embodiment from about 10 to about 30%, by weight on adry filament basis, and in further embodiments from about 10 to about20%, by weight on a dry filament basis.

Non-limiting examples of nonsteroidal anti-inflammatory drugs (NSAIDs)can include acetaminophen, celecoxib, diclofenac, etodolac, fenoprofencalcium, ibuprofen, ketoprofen, mefenamic acid, meloxicam, naproxen,tolmetin sodium, indomethacin, and combinations thereof. In oneembodiment, the health care active can be naproxen. NSAIDs can bepresent in the filament from about 1% to about 60%, by weight on a dryfilament basis, alternatively from about 5% to about 50%, by weight on adry filament basis, and alternatively from about 10% to about 40%, byweight on a dry filament basis.

Non-limiting examples of salicylates can include aspirin, magnesiumsalicylate, salsalate, diflunisal, and combinations thereof. Salicylatescan be present in the filament from about 1% to about 60%, by weight ona dry filament basis, alternatively from about 5% to about 50%, byweight on a dry filament basis, and alternatively from about 10% toabout 40%, by weight on a dry filament basis.

Non-limiting examples of opioid analgesics can include codeine,hydromorphone hydrochloride, methadone hydrochloride, morphine sulfate,oxycodone hydrochloride, and combinations thereof. Opioid analgesics canbe present in the filament from about 0.5% to about 40%, by weight on adry filament basis, alternatively from about 0.5% to about 30%, byweight on a dry filament basis, and alternatively from about 1% to about20%, by weight on a dry filament basis.

The filament of the present invention can comprise miscellaneous centralnervous system stimulants. Non-limiting examples of miscellaneous CNSstimulants can include nicotine, picrotoxin, pentylenetetrazol, andcombinations thereof. Miscellaneous central nervous system stimulantscan be present in the filament from about 0.1% to about 60%, by weighton a dry filament basis, alternatively from about 1% to about 40%, byweight on a dry filament basis, and alternatively from about 5% to about30%, by weight on a dry filament basis.

Anti-Infective Agents

In an embodiment the one or more health care actives can be ananti-infective agent. Non-limiting examples of anti-infective agents caninclude antivirals, antimicrobials, and combinations thereof.Anti-infective agents can be used to treat pathogenic infections.Non-limiting examples of pathogenic infections can include tuberculosis,pneumonia, food poisoning, tetanus, typhoid fever, diphtheria, syphilis,meningitis, sepsis, leprosy, whooping cough, lyme disease, gangrene,urinary tract infections, traveler's diarrhea, methicillin-resistantStaphylococcus aureus (MRSA), gonorrhea, scarlet fever, cholera, herpes,hepatitis, human immunodeficiency virus (HIV), influenza, measles,mumps, human papillomavirus, polio virus, giardia, malaria, tapeworm,roundworm, and combinations thereof. Anti-infective agents may provideanti-infective benefits. Non-limiting examples of anti-infectivebenefits can include treating pathogenic infection symptoms.Non-limiting examples of pathogenic infection symptoms can includefever, inflammation, nausea, vomiting, loss of appetite, abnormal whiteblood cell count, diarrhea, rash, skin lesions, sore throat, headache,stomach ache, muscle pain, fatigue, cough, chest pain, difficultybreathing, burning during urination, and combinations thereof.

Non-limiting examples of antivirals can include ganciclovir,valganciclovir, acyclovir, famciclovir, valacyclovir, amantadine,ribavirin, rimantidine HCl, oseltamivir phosphate, adefovir dipivoxil,entecavir, and combinations thereof. Antivirals can be present in thefilament from about 0.5% to about 60%, by weight on a dry filamentbasis, alternatively from about 1% to about 30%, by weight on a dryfilament basis, and alternatively from about 5% to about 20%, by weighton a dry filament basis. In certain embodiments, the antivirals can bepresent in the filament from about 20% to about 60%, by weight on a dryfilament basis, and alternatively from about 30% to about 60%, by weighton a dry filament basis, and in a further embodiment from about 40% toabout 60%, by weight on a dry filament basis.

Non-limiting examples of antimicrobials can include nitroimidazoleantibiotics, tetracyclines, penicillin-based antibiotics such asamoxicillin, cephalosporins, carbopenems, aminoglycosides, macrolideantibiotics, lincosamide antibiotics, 4-quinolones, fluoroquinolones,rifamycins, rifaximi, nitrofurantoin, and combinations thereof.Antimicrobials can be present in the filament from about 1% to about50%, by weight on a dry filament basis, alternatively from about 5% toabout 40%, by weight on a dry filament basis, and alternatively fromabout 10% to about 30%, by weight on a dry filament basis.

Nutritional Agents

In an embodiment the one or more health care actives can be anutritional agent. Non-limiting examples of nutritional agents caninclude vitamins, minerals and electrolytes, dietary fiber, fatty acids,and combinations thereof. Nutritional agents can be used to treatnutritional deficiencies. Non-limiting examples of nutritionaldeficiencies can include a depressed immune system, birth defects innewborns, heart disease, cancer, Alzheimer's disease, eye diseases,nightblindness, osteoporosis, beriberi, pellagra, scurvy, rickets,alcoholism, irritable bowel syndrome (IBS), low hormone levels,hypertension, and combinations thereof. Nutritional agents may provide anutritional benefit. Non-limiting examples of nutritional benefits caninclude disease prevention, lowering cholesterol, increased energy andalertness, reducing the effects of aging, restoring digestive balance,and treating nutritional deficiency symptoms and combinations thereof.Non-limiting examples of nutritional deficiency symptoms can includefatigue, muscle weakness, irritability, hair loss, unintentional weightloss, unintentional weight gain, decreased mental ability, stress, bonefractures, decreased eyesight, decreased rate of wound healing,hyperactivity, dermatitis, muscle cramping, cardiac arrhythmias,depression, and combinations thereof.

Non-limiting examples of vitamins can include vitamin C, vitamin D₂(cholecalciferol), vitamin D₃ (ergocalciferol), vitamin A, vitamin B₁(thiamine), vitamin B₂ (riboflavin), vitamin B₃ (niacin), B₅(pantothenic acid), vitamin B₆ (pyridoxine, pyridoxal, or pyridoxamine),vitamin B₇ (biotin), vitamin B₉ (folic acid), Vitamin B₁₂(cyanocobalmin), vitamin E, and combinations thereof. In one embodiment,the health care active can be vitamin B₉. Vitamins can be present in thefilament from about 1% to about 85%, by weight on a dry filament basis,alternatively from about 5% to about 60%, by weight on a dry filamentbasis, and alternatively from about 10% to about 50%, by weight on a dryfilament basis.

Non-limiting examples of minerals and electrolytes can include zinc,iron, calcium, iodine, copper, magnesium, potassium, chromium, selenium,and combinations thereof. Minerals and electrolytes can be present inthe filament from about 1% to about 85%, by weight on a dry filamentbasis, alternatively from about 5% to about 60%, by weight on a dryfilament basis, and alternatively from about 10% to about 50%, by weighton a dry filament basis.

Non-limiting examples of antioxidants can include, but are not limitedto, polyphenols, superfruits, and combinations thereof. Antioxidants canbe present in the filament from about 0.5% to about 50%, by weight on adry filament basis, alternatively from about 1% to about 40%, by weighton a dry filament basis, and alternatively from about 10% to about 30%,by weight on a dry filament basis.

Non-limiting examples of health care actives containing polyphenols caninclude tea extract, coffee extract, turmeric extract, grapeseedextract, blueberry extract, and combinations thereof. Nonlimitingexamples of superfruits can include açaí, blueberry, cranberry, grape,guarana, mangosteen, noni, pomegranate, seabuckthorn, wolfberry (goji),acerola (Barbados cherry, Malpighia emarginata, Malpighia glabra),bayberry (yumberry, Myrica rubra), bilberry (Vaccinium myrtillus), blackraspberry (Rubus occidentalis), black chokeberry (“aronia”, Aroniamelanocarpa), blackcurrant (Ribes nigrum), camu camu (Myrciaria dubia),sour (tart) cherry (Prunus cerasus), cupuacu (Theobroma grandiflorum),durian (Durio kutejensis), elderberry (Sambucus canadensis, Sambucusnigra), red guava (Psidium guajava, many species), Indian gooseberry(amalaka, amla, Phyllanthus emblica), kiwifruit (Actinidia deliciosa),lingonberry (Vaccinium vitis-idaea), lychee (Litchi chinensis),muscadine grape (Vitis rotundifolia), papaya (Carica papaya), pomelo(Citrus maxima), saskatoon berry (Amelanchier alnifolia, Nutt), tamarind(Tamarindus indica), wild cherry (Prunus avium) andyuzu (Citrusichangensis, C. reticulata) and combinations thereof.

Non-limiting examples of fatty acids can include Omega-3 fatty acids,Omega-6 fatty acids, and combinations thereof. Fatty acids can bepresent in the filament from about 1% to about 60%, by weight on a dryfilament basis, alternatively from about 5% to about 40%, by weight on adry filament basis, and alternatively from about 5% to about 20%, byweight on a dry filament basis.

Non-limiting examples of Omega-3 fatty acids can include alpha-linoleicacid, alpha-linolenic acid, stearidonic acid, eicosatrienoic acid,eicosatetraenoic acid, eicosapentaenoic acid, docosapentaenoic acid,docosahexaenoic acid, tetracosapentaenoic acid, tetracosahexaenoic acid,and combinations thereof.

Non-limiting examples of Omega-6 fatty acids can include linoleic acid,gamma-linolenic acid, eicosadienoic acid, dihomo-gamma-linolenic acid,arachidonic acid, docosadienoic acid, adrenic acid, docosapentaenoicacid, and combinations thereof.

Overall Wellbeing Agents

In an embodiment the one or more health care actives can be an overallwellbeing agent. Non-limiting examples of overall wellbeing agents caninclude energy boosting agents, probiotics, prebiotics, dietary fiber,enzymes, vitamins, minerals and electrolytes, antioxidants, fatty acids,and combinations thereof. Probiotics, prebiotics, dietary fiber,enzymes, vitamins, minerals and electrolyntes, antioxidants, and fattyacids are described herein.

Overall wellbeing agents can be used to provide one or more overallwellbeing benefits. Non-limiting examples of overall wellbeing benefitscan include improving and/or maintaining respiratory health,gastrointestinal health, immune health, mobility and joint health,cardiovascular health, skin health, oral/dental health, hair health, eyehealth, reproductive health including menstrual health, ear, nose andthroat health, mental health, energy, normal blood glucose levels,muscle strength, and combinations thereof.

The filament of the present invention can comprise energy boostingagents. Energy boosting actives may provide mammals with more energy ora perception of more energy.

Non-limiting examples of energy boosting agents can include, but are notlimited to, caffeine, green and black tea, taurine, Rhodiola rosea,Siberian ginseng (Eleutherococcus senticosus), CoQ10, L-carnitine,L-Theanine, guarana (Paullinia cupana), Schizandra chinensis, yerba mate(Ilex paraguariensis), goji berry/Wolfberry (Lycium barbarum and L.chinense), quercetin (a plant-derived flavonol), amalaki/Indiangooseberry (Phyllanthus emblica), açaí (from genus Euterpe), maca(Lepidium meyenii), Ginkgo biloba, glucuronolactone, panax ginseng (fromspecies within Panax, a genus of 11 species of slow-growing perennialplants with fleshy roots, in the family Araliaceae), Echinacea (genus ofnine species of herbaceous plants in the Family Asteraceae), rooibos(Aspalathus linearis), DHEA, noni (Morinda citrifolia), mangosteen(Garcinia mangostana), and combinations thereof. Energy boosting agentscan be present in the filament from about 0.5% to about 70%, by weighton a dry filament basis, alternatively from about 1% to about 50%, byweight on a dry filament basis, and alternatively from about 10% toabout 40%, by weight on a dry filament basis.

Excipients

The personal health care article and filaments can include one or moreexcipients. Non-limiting examples of excipients can includefilament-forming materials, aesthetic agents, and combinations thereof.Non-limiting examples filament-forming materials can include backbonematerials, extensional aids, plasticizers, crosslinking agents, andcombinations thereof. Non-limiting examples of aesthetic agents caninclude flavors, colorants, sensates, sweeteners, salivation agents, andcombinations thereof.

Backbone Material

The backbone material can comprise any suitable material that exhibitsproperties suitable for making a filament. Non-limiting examples ofbackbone materials can include polymers, sugars, sugar alcohols, andcombinations thereof. In an embodiment the filament comprises two ormore different backbone materials. In another embodiment the filamentcomprises three or more different backbone materials. In one embodiment,the polymer can function as a backbone material and in certainembodiments can also provide a health benefit

The filament can comprise from about 10% to about 80% backbone material,by weight on a dry filament basis, in another embodiment from about 15%to about 75% backbone material, by weight on a dry filament basis, instill another embodiment from about 20% to about 70% backbone material,by weight on a dry filament basis, in another embodiment from about 20%to about 65% backbone material, by weight on a dry filament basis, instill another embodiment from about 25% to about 65%, by weight on a dryfilament basis, and in a further embodiment from about 30% to about 60%backbone material, by weight on a dry filament basis.

Polymer

In one embodiment, the backbone material can comprise a polymer.Non-limiting examples of polymers can include naturally sourcedpolymers, synthetic polymers, and combinations thereof.

Non-limiting examples of naturally sourced polymers can includealginates, gums, protein based polymers, starch based polymers, nativestarches, modified starches, fiber polymers, other naturally sourcedpolymers, and combinations thereof.

Non-limiting examples of alginates can include ammonium alginate,calcium alginate, potassium alginate, propylene glycol alginate, andcombinations thereof.

Non-limiting examples of gums can include acacia gum, carrageenan,tragacanth gum, guar gum, locust bean gum, xanthan gum, gellan gum, andcombinations thereof.

Non-limiting examples of protein based polymers can include whey proteinisolate, soy protein isolate, egg albumin, casein, collagen, glutelin,gelatin, gluten, zein, and combinations thereof.

Non-limiting examples of starch based polymers can include cereals,tubers, roots, legumes, fruits, and combinations thereof.

Non-limiting examples of native starches can include can include waxy orhigh amylase varieties of corn, pea, potato, banana, barley, wheat,rice, sago, amaranth, tapioca, arrowroot, canna, sorghum, andcombinations thereof.

Non-limiting examples of modified starches can include hydroxypropylstarch, maltodextrin, high amylose starch, and combinations thereof.

Non-limiting examples of fiber polymers can include pectins,fructo-oligosaccharides, inulin, agar, beta-glucans, dextrins, lignin,celluloses, non-starch polysaccharides, reduced starch, polycarbophil,citrus fiber, and combinations thereof.

Non-limiting examples of other naturally sourced polymers can includeagar, pullulan, chitin, chitosan, shellac, and combinations thereof.

Non-limiting examples of synthetic polymers can include cellulosederivatives, carbomers, polymethacrylates, other synthetic polymers, andcombinations thereof.

Non-limiting examples of cellulose derivatives can includehydroxyethylmethyl cellulose, hydroxylpropylmethyl cellulose,hydroxypropyl cellulose, hydroxypropylethyl cellulose, methylcellulose,hydroxypropyl methylcellulose, and combinations thereof.

Non-limiting examples of carbomers can include carbomer 934, carbomer934P, carbomer 940, carbomer 94, carbomer 1342, carbomer copolymers,carbomer homopolymers, carbomer interpolymers, and combinations thereof.Some carbomers are available commercially as Carbopol® 934P NF polymer,Carbopol® 971P NF polymer, and Carbopol® 974P NF polymer.

Non-limiting examples of polymethacrylates can include ammoniomethacrylate copolymer, basic butylated methacrylate copolymer,methacrylic acid-methyl methacrylate copolymer (1:1), methacrylicacid-ethyl acrylate copolymer (1:1), methacrylic acid-ethyl acrylatecopolymer (1:1), methacrylic acid-methyl methacrylate copolymer (1:2),polyacrylate dispersion 30%, methacrylic acid copolymer, aminomethacrylate copolymer, ammonio methacrylate copolymer, ammoniomethacrylate copolymer dispersion, ethyl acrylate and methylmethacrylate copolymer, and combinations thereof. Some polymethacrylatesare available commercially as Eudragit® E 12.5, Eudragit® E 100,Eudragit® E PO, Eudragit® L 12.5 P, Eudragit® L 12.5, Eudragit® L 100,Eudragit® L 100-55, Eudragit® L 30 D-55, Eudragit® S 12.5 P, Eudragit® S12.5, Eudragit® S 100, Eudragit® FS 30 D, Eudragit® RL 12.5, Eudragit®RL 100, Eudragit® RL PO, Eudragit® RL 30 D, Eudragit® RS 12.5, Eudragit®RS 100, Eudragit® RS PO, Eudragit® RS 30 D, Eudragit® NE 30 D, Eudragit®NE 40 D, Eudragit® NM 30 D, Eastacryl™ 30 D, Kollicoat® MAE 30 DP,Kollicoat® MAE 100 P, Acryl-EZE®, Acryl-EZE® 93 A, and Acryl-EZE® MP.

Non-limiting examples of other synthetic polymers can include polyvinylalcohol, carboxyvinyl polymers, polyvinyl pyrrolidones, polyethyleneoxide, polyoxyethylene, and combinations thereof.

In one embodiment, the polymer of the present invention is selected suchthat its weight average molecular weight is from about 20,000 Daltons(Da) to about 10,000,000 Da, in an embodiment from about 100,000 Da toabout 5,000,000 Da, in yet another embodiment from about 500,000 Da toabout 4,000,000 Da, and in still another embodiment from about 1,000,000Da to about 3,000,000 Da. The weight average molecular weight iscomputed by summing the weight average molecular weight of each backbonematerial raw material multiplied by their respective relative weightpercentages by weight of the total weight of polymers present within thefilament.

In one embodiment, the backbone material is polyvinyl alcohol with aweight average molecular weight from about 10,000 Da to about 250,000Da, in another embodiment from about 15,000 Da to about 200,000 Da, andin another embodiment from about 20,000 Da to about 150,000 Da.

In one embodiment, the backbone material is selected from the groupconsisting of alginates, starch based polymers, native starches,modified starches, and combinations thereof with a weight averagemolecular weight from about 1,000,000 Da to about 6,000,000 Da, inanother embodiment from about 1,500,000 Da to about 5,000,000 Da, and inanother embodiment from about 2,000,000 Da to about 4,000,000 Da.

In one embodiment, the backbone material is selected from the groupconsisting of polyvinyl alcohol, pullulan, pectin, corn starch, modifiedcorn starch, hydroxypropyl methylcellulose, and combinations thereof.

Sugar

In one embodiment, the backbone material can be a sugar. Non-limitingexamples of sugar can include monosaccharides, disacchairdes, trioses,tetroses, pentoses, hexoses, heptoses, octoses, nonose, sugar alcohols,and combinations thereof.

Non-limiting examples of monosaccharides can include glucose, fructose,and combinations thereof.

Non-limiting examples of disaccharides can include sucrose, maltose,lactose, high fructose corn syrup solids, trehalose, cellobiose,gentiobiose, isomaltose, kojibiose, laminaribiose, mannobiose,melibiose, nigerose, rutinose, xylobiose, lactulose and combinationsthereof.

Non-limiting examples of trioses can include glyceraldehydes,dihydroxyacetone, and combinations thereof.

Non-limiting examples of tetroses can include erythrose, threose,erythrulose, and combinations thereof.

Non-limiting examples of pentoses can include arabinose, lyxose, ribose,xylose, ribulose, xylulose, and combinations thereof.

Non-limiting examples of hexoses can include allose, altrose, galactose,glucose, gulose, idose, mannose, talose, fructose, psicose, sorbose,tagatose, and combinations thereof.

Non-limiting examples of heptoses can include mannoheptulose,sedoheptulose, and combinations thereof.

Non-limiting examples of octoses can include octolose,2-keto-3-deoxy-manno-octonate, and combinations thereof. A non-limitingexample of nonose can include sialose.

Non-limiting examples of sugar alcohols can include sorbitol, mannitol,lactitol, isomalt, arabitol, erythritol, glycerol, isomalt, lactitol,maltitol, xylitol, and combinations thereof.

Extensional Aids

In one embodiment, the filament can optionally comprise an extensionalaid. Non-limiting examples of extensional aids can include polymers,other extensional aids, and combinations thereof.

In one embodiment, the extensional aids have a weight average molecularweight of at least about 500,000 Da. In another embodiment, the weightaverage molecular weight of the extensional aid is from about 500,000 toabout 25,000,000, in another embodiment from about 800,000 to about22,000,000, in yet another embodiment from about 1,000,000 to about20,000,000, and in another embodiment from about 2,000,000 to about15,000,000. The high molecular weight extensional aids are preferred insome embodiments of the invention due to the ability to increaseextensional melt viscosity and reducing melt fracture.

The extensional aid, when used in meltblowing, is added to thecomposition of the present invention in an amount effective to visiblyreduce the melt fracture and capillary breakage of filaments during thespinning process such that substantially continuous filaments havingrelatively consistent diameter can be melt spun. Regardless of theprocess employed to produce filaments, the extensional aids, when used,can be present from about 0.001% to about 10%, by weight on a dryfilament basis, in one embodiment, and in another embodiment from about0.005 to about 5%, by weight on a dry filament basis, in yet anotherembodiment from about 0.01 to about 1%, by weight on a dry filamentbasis, and in another embodiment from about 0.05% to about 0.5%, byweight on a dry filament basis.

Non-limiting examples of polymers that can optionally be used asextensional aids can include alginates, carrageenans, pectin, chitin,guar gum, xanthum gum, agar, gum arabic, karaya gum, tragacanth gum,locust bean gum, alkylcellulose, hydroxyalkylcellulose,carboxyalkylcellulose, and mixtures thereof.

Nonlimiting examples of other extensional aids can include carboxylmodified polyacrylamide, polyacrylic acid, polymethacrylic acid,polyvinyl alcohol, polyvinylacetate, polyvinylpyrrolidone, polyethylenevinyl acetate, polyethyleneimine, polyamides, polyalkylene oxidesincluding polyethylene oxide, polypropylene oxide, polyethylenepropyleneoxide, and mixtures thereof.

Plasticizer

In an embodiment, the filament can optionally comprise a plasticizer.Non-limiting examples of plasticizers can include polyols,polycarboxylic acids, polyesters, other suitable plasticizers, andcombinations thereof.

Non-limiting examples of polyols can include glycerin, propylene glycol,polyethylene glycol, sugar alcohols including sorbitol, mannitol, andlactitol; mono di- and oligo-saccharides such as fructose, glucose,sucrose, maltose, lactose, and high fructose corn syrup solids, ascorbicacid, and combinations thereof.

Non-limiting examples of polycarboxylic acids can include citric acid,succinic acid, and combinations thereof.

Non-limiting examples of polyesters can include glycerol triacetate,diethyl phthalate, triethyl citrate, tributyl citrate, acetyl triethylcitrate, acetyl tributyl citrate, and combinations thereof.

Non-limiting examples of other suitable platicizers of the presentinvention include, but are not limited to, alkyl and allyl phthalates;lactates (e.g., sodium, ammonium and potassium salts); lactic acid;soluble collagen; modified protein; monosodium L-glutamate; proteins andamino acids such as glutamic acid, aspartic acid, and lysine; hydrogenstarch hydrolysates; other low molecular weight esters (e.g., esters ofC2-C10 alcohols and acids); and any other plasticizer known to oneskilled in the art of the food, dietary supplements, and pharmaceuticalindustries; and combinations thereof.

Crosslinking Agent

In one embodiment the filament can optionally comprise a crosslinkingagent that is suitable for crosslinking one or more of the backbonematerials. Non-limiting examples of crosslinking agents can includeenzymatic crosslinking agents, ionic crosslinking agent, andcombinations thereof. Non-limiting examples of ionic crosslinking agentscan include calcium carbonate, calcium citrate, calcium citrate malate,calcium chloride, and combinations thereof. In one embodiment, thecrosslinking agents can be present from about 0.01% to about 5%, byweight on a dry filament basis, in another embodiment from about 0.1 toabout 3%, by weight on a dry filament basis, and in yet anotherembodiment from about 0.25 to about 2.5%, by weight on a dry filamentbasis.

Aesthetic Agents

The filaments of the present invention can optionally comprise one ormore aesthetic agents. The one or more aesthetic agents can be selectedfrom the group consisting of flavors, colorants, sensates, sweeteners,salivation agents, and combinations thereof. All aesthetic agents can bepresent from about 0.001% to about 80%, by weight on a dry filamentbasis, in another embodiment from about 0.005% to about 60%, by weighton a dry filament basis, in still another embodiment from about 0.05% toabout 55%, by weight on a dry filament basis, and in another embodimentfrom about 0.1% to about 50%, by weight on a dry filament basis. Allaesthetic agents can be present from about 0.001% to about 60%, byweight of the article, in another embodiment from about 0.005% to about50%, by weight of the article, in still another embodiment from about0.05% to about 40%, by weight of the article, and in another embodimentfrom about 0.1% to about 35%, by weight of the article.

Flavors

The filament can optionally include one or more flavors. Non-limitingexamples of flavors that can be used in the present invention caninclude natural flavoring agents, artificial flavoring agents,artificial extracts, natural extracts and combination thereof.Non-limiting examples of flavors can include vanilla, honey, lemon,lemon honey, cherry vanilla, peach, honey ginger, chamomile, cherry,cherry cream, mint, vanilla mint, dark berry, black berry, raspberry,peppermint, spearmint, honey peach, acai berry, cranberry, honeycranberry, tropical fruit, dragon fruit, wolf berry, red stem mint,pomegranate, black current, strawberry, lemon, lime, peach ginger,orange, orange cream, cream sickle, apricot, anethole, ginger, jackfruit, star fruit, blueberry, fruit punch, lemon grass, chamomile lemongrass, lavender, banana, strawberry banana, grape, blue raspberry, lemonlime, coffee, espresso, cappuccino, honey, wintergreen mint, bubble gum,tart honey lemon, sour lemon, green apple, boysenberry, rhubarb,strawberry rhubarb, persimmon, green tea, black tea, red tea, white tea,honey lime, cherry lime, apple, tangerine, grapefruit, kiwi, pear,vanillin, ethyl vanillin, maltol, ethyl-maltol, pumpkin, carrot cake,white chocolate raspberry, chocolate, white chocolate, milk chocolate,dark chocolate, chocolate marshmallow, apple pie, cinnamon, hazelnut,almond, cream, creme brûlée, caramel, caramel nut, butter, buttertoffee, caramel toffee, aloe vera, whiskey, rum, cocoa, licorice,pineapple, guava, melon, watermelon, elder berry, mouth cooler,raspberries and cream, peach mango, tropical, cool berry, lemon ice,nectar, spicy nectar, tropical mango, apple butter, peanut butter,tangerine, tangerine lime, marshmallow, cotton candy, apple cider,orange chocolate, adipic acid, citral, denatonium benzoate, ethylacetate, ethyl lactate, ethyl maltol, ethylcellulose, fumaric acid,leucine, malic acid, menthol, methionine, monosodium glutamate, sodiumacetate, sodium lactate, tartaric acid, thymol, and combinationsthereof.

Flavors can be present from about 0.05% to about 50%, by weight of thearticle, in another embodiment from about 0.01% to about 30%, by weighton a dry filament basis, in still another embodiment from about 0.2% toabout 20%, by weight on a dry filament basis, and in another embodimentfrom about 0.1% to about 15%, by weight on a dry filament basis. Flavorscan be present from about 0.05% to about 5%, by weight of the article,in another embodiment from about 0.01% to about 3%, by weight of thearticle, in still another embodiment from about 0.2% to about 2%, byweight of the article, and in another embodiment from about 0.1% toabout 1.5%, by weight of the article.

Colorants

The filament can optionally include one or more colorants. In anembodiment, the colorants provide a visual signal when the filament isexposed to conditions of intended use. Non-limiting examples colorantsthat may be used in the present invention include FD&C blue #1, FD&Cblue #2, D&C blue #4, D&C blue #9, FD&C green #3, D&C green #5, D&Cgreen #6, D&C green #8, D&C orange #4, D&C orange #5, D&C orange #10,D&C orange #11, FD&C red #3, FD&C red #4, D&C red #6, D&C red #7, D&Cred #17, D&C red #21, D&C red #22, D&C red #27, D&C red #28, D&C red#30, D&C red #31, D&C red #33, D&C red #34, D&C red #36, D&C red #39,FD&C red #40, D&C violet #2, FD&C yellow #5, FD&C yellow #6, D&C yellow#7, Ext. D&C yellow #7, D&C yellow #8, D&C yellow #10, D&C yellow #11,and combinations thereof. Colorants can be present from about 0.05% toabout 2%, by weight on a dry filament basis or the article, in anotherembodiment from about 0.01% to about 2%, by weight on a dry filamentbasis or the article, and in still another embodiment from about 0.02%to about 1.5%, by weight on a dry filament basis or the article.

Sensates

The filaments can optionally include one or more sensates. Non-limitingexamples of sensates can include cooling sensates, warming sensates,tingling sensates, and combinations thereof. Sensates are useful todeliver signals to the user.

Non-limiting examples of cooling sensates can include WS-23(2-Isopropyl-N,2,3-trimethylbutyramide), WS-3(N-Ethyl-p-menthane-3-carboxamide), WS-30(1-glyceryl-p-mentane-3-carboxylate), WS-4(ethyleneglycol-p-methane-3-carboxylate), WS-14(N-t-butyl-p-menthane-3-carboxamide), WS-12(N-(4-,ethoxyphenyl)-p-menthane-3-carboxamide), WS-5(Ethyl-3-(p-menthane-3-carboxamido)acetate, Menthone glycerol ketal(sold as Frescolat® MGA by Haarmann & Reimer), (−)-Menthyl lactate (soldas Frescolat® ML by Haarmann & Reimer),(−)-Menthoxypropane-1,2-diol(sold as Coolant Agent 10 by TakasagoInternational), 3-(1-menthoxy)propane-1,2-diol,3-(1-Menthoxy)-2-methylpropane-1,2-diol, (−)-Isopulegol is sold underthe name “Coolact P® ” by Takasago International., cis & transp-Menthane-3,8-diols(PMD38)—Takasago International, Questice® (menthylpyrrolidone carboxylate),(1R,3R,4S)-3-menthyl-3,6-dioxaheptanoate—Firmenich, (1R,2S,5R)-3-menthylmethoxyacetate—Firmenich, (1R,2S,5R)-3-menthyl3,6,9-trioxadecanoate—Firmenich, (1R,2S,5R)-menthyl11-hydroxy-3,6,9-trioxaundecanoate—Firmenich, (1R,2S,5R)-3-menthyl(2-hydroxyethoxy)acetate—Firmenich, Cubebol—Firmenich, Icilin also knownas AG-3-5, chemical name1-[2-hydroxyphenyl]-4-[2-nitrophenyl-]1-1,2,3,6-tetrahydropyrimidine-2-one),4-methyl-3-(1-pyrrolidinyl)-2[5H]-furanone, Frescolat ML—menthyllactate, Frescolat MGA—menthone glycerin acetal, Peppermint oil,Givaudan 180, L-Monomenthyl succinate, L-monomenthyl glutarate,3-1-menthoxypropane-1,2-diol—(Coolact 10), 2-1-menthoxyethanol (Cooltact5), TK10 Coolact (3-1-Menthoxy propane-1,2-diol), Evercool 180(N-p-benzeneacetonitrile-menthane carboxamide), and combinationsthereof. Cooling sensates can be present from about 0.005% to about 60%,by weight on a dry filament basis, in another embodiment from about0.05% to about 50%, by weight on a dry filament basis, and in stillanother embodiment from about 0.01% to about 40%, by weight on a dryfilament basis. Cooling sensates can be present from about 0.005% toabout 10%, by weight of the article, in another embodiment from about0.05% to about 7%, by weight of the article, and in still anotherembodiment from about 0.01% to about 5%, by weight of the article.

Non-limiting examples of warming sensates can include TK 1000, TK 1 MM,Heatenol—Sensient Flavors, Optaheat—Symrise Flavors, Cinnamon,Polyethylene glycol, Capsicum, Capsaicin, Curry, FSI Flavors,Isobutavan, Ethanol, Glycerin, Nonivamide 60162807, Hotact VEE, Hotact1MM, piperine, optaheat 295 832, optaheat 204 656, optaheat 200 349, andcombinations thereof. Warming sensates can be present from about 0.005%to about 60%, by weight on a dry filament basis, in another embodimentfrom about 0.05% to about 50%, by weight on a dry filament basis, and instill another embodiment from about 0.01% to about 40%, by weight on adry filament basis. Warming sensates can be present from about 0.005% toabout 10%, by weight of the article, in another embodiment from about0.05% to about 7%, by weight of the article, and in still anotherembodiment from about 0.01% to about 5%, by weight of the article.

Non-limiting examples of tingling sensates can include sichuan pepper,hydroxy alpha sanshool, citric acid, Jambu extracts, spilanthol, andcombinations thereof. Tingling sensates can be present from about 0.005%to about 10%, by weight on a dry filament basis or the article, inanother embodiment from about 0.01% to about 7%, by weight on a dryfilament basis or the article, and in still another embodiment fromabout 0.015% to about 6%, by weight on a dry filament basis or thearticle.

Sweeteners

The filament can optionally include one or more sweeteners. Sweetenerscan be natural or artificial. Non-limiting examples of sweeteners caninclude nutritive sweeteners, sugar alcohols, synthetic sweeteners, highintensity natural sweeteners, and combinations thereof. All sweetenerscan be present from about 0.05% to about 60%, by weight on a dryfilament basis or the article, in another embodiment from about 0.1% toabout 50%, by weight on a dry filament basis or the article, in yetanother embodiment from about 1% to about 10%, by weight on a dryfilament basis or the article.

Non-limiting examples of nutritive sweeteners can include sucrose,dextrose, glucose, fructose, lactose, tagatose, maltose, trehalose, andcombinations thereof. Nutritive sweeteners can be present from about0.1% to about 60%, by weight on a dry filament basis or the article, inanother embodiment from about 1% to about 50%, by weight on a dryfilament basis or the article, and in a further embodiment from about0.1% to about 10%, by weight on a dry filament basis or the article.

Non-limiting examples of sugar alcohols can include xylitol, sorbitol,mannitol, maltitol, lactitol, isomalt, erythritol, and combinationsthereof. Sugar alcohols can be present from about 0.1% to about 60%, byweight on a dry filament basis or the article, in another embodimentfrom about 0.11% to about 50%, by weight on a dry filament basis or thearticle, and in a further embodiment from about 0.1% to about 10%, byweight on a dry filament basis or the article.

Non-limiting examples of synthetic sweeteners can include aspartame,acesulfame potassium, alitame, sodium saccharin, sucralose, neotame,cyclamate, and combinations thereof. Synthetic sweeteners can be presentfrom about 0.05% to about 10% by weight on a dry filament basis or thearticle, in another embodiment from about 0.1% to about 5%, by weight ona dry filament basis or the article, and in a further embodiment fromabout 0.25% to about 4%, by weight on a dry filament basis or thearticle.

Non-limiting examples of high intensity natural sweeteners can includeneohesperidin dihydrochalcone, stevioside, rebaudioside A, rebaudiosideC, dulcoside, monoammonium glycrrhizinate, thaumatin, and combinationsthereof. High intensity natural sweeteners can be present from about0.05% to about 10% by weight on a dry filament basis or the article, inanother embodiment from about 0.1% to about 5%, by weight on a dryfilament basis or the article, and in a further embodiment from about0.25% to about 4%, by weight on a dry filament basis or the article.

Salivation Agents

The filament can optionally include one or more salivation agents.Non-limiting examples of salivation agents include formula (I):

wherein R₁ represents C1-C2 n-alkyl; R₂ is 2-methyl-1-propyl and R₃ ishydrogen, or R₂ and R₃ taken together is a moiety (designated by thedashed lines) having the formula —(CH₂)_(n)— wherein n is 4 or 5, andcombinations thereof.

In an embodiment, the salivating agent comprises a material wherein R₂is 2-methyl-1-propyl and R₃ is hydrogen, in another embodiment thesalivating agent comprises a material wherein R₁ is Cl n-alkyl, R₂ is2-methyl-1-propyl and R₃ is hydrogen. In another embodiment, thesalivating agent comprises trans-pellitorin, a chemical having astructure according to formula (II):

In another embodiment, the salivation agent could include sodiumbicarbonate, sodium chloride, trans pelitorin, and combinations thereof.Salivation agents can be present from about 1% to about 60%, by weighton a dry filament basis, in another embodiment from about 1% to about50%, by weight on a dry filament basis, and in still another embodimentfrom about 1% to about 40%, by weight on a dry filament basis.Salivation agents can be present from about 0.005% to about 10%, byweight of the article, in another embodiment from about 0.01% to about7%, by weight of the article, and in still another embodiment from about0.015% to about 6%, by weight of the article.

Lathering porous dissolvable solid substrates for the purposes oflathering and/or cleaning comprise from about 10% to about 75%, in oneembodiment from about 30% to about 70%, and in another embodiment fromabout 40% to about 65% by weight of the personal care article ofsurfactant; wherein the surfactant comprises one or more surfactantsfrom Group I, wherein Group I includes anionic surfactants which aresuitable for use in hair care or other personal care compositions, andoptionally one or more surfactants from Group II, wherein Group IIincludes a surfactant selected from the group consisting of amphoteric,zwitterionic and combinations thereof suitable for use in hair care orother personal care compositions; wherein the ratio of Group I to GroupII surfactants is from about 100:0 to about 30:70. In another embodimentof the present invention the ratio of Group I to Group II surfactants isfrom about 85:15 to about 40:60. In yet another embodiment of thepresent invention the ratio of Group I to Group II surfactants is fromabout 70:30 to about 55:45.

Non limiting examples of anionic surfactants are described in U.S. Pat.Nos. 2,486,921; 2,486,922; and 2,396,278. The anionic surfactant can beselected from the group consisting of alkyl and alkyl ether sulfates,sulfated monoglycerides, sulfonated olefins, alkyl aryl sulfonates,primary or secondary alkane sulfonates, alkyl sulfosuccinates, acidtaurates, acid isethionates, alkyl glycerylether sulfonate, sulfonatedmethyl esters, sulfonated fatty acids, alkyl phosphates, acylglutamates, acyl sarcosinates, alkyl lactylates, anionicfluorosurfactants, sodium lauroyl glutamate, and combinations thereof.

Non limiting examples of suitable zwitterionic or amphoteric surfactantsare described in U.S. Pat. Nos. 5,104,646 (Bolich 11'. et al.),5,106,609 (Bolich 11'. et al.). The zwitterionic surfactant can beselected from the group consisting of cocamidoethyl betaine,cocamidopropylamine oxide, cocamidopropyl betaine, cocamidopropyldimethylaminohydroxypropyl hydrolyzed collagen, cocamidopropyldimoniumhydroxypropyl hydrolyzed collagen, cocamidopropyl hydroxysultaine,cocobetaineamido amphopropionate, coco-betaine, coco-hydroxysultaine,coc%leamidopropyl betaine, coco-sultaine, lauramidopropyl betaine,lauryl betaine, lauryl hydroxysultaine, and lauryl sultaine. Theamphoteric surfactant can be selected from the group consisting ofsodium cocoamphoacetate, sodium cocoamphodiacetate, sodium lauro amphoacetate, sodium lauroamphodiacetate, ammonium lauroamphoacetate,ammonium cocoamphoacetate, triethanolamine lauroamphoacetate, andtriethanolamine cocoamphoacetate.

Additional suitable Group I and Group II surfactants include thosedisclosed in U.S. Patent Application No. 61/1120,765 and thosesurfactants disclosed in McCutcheon's Detergents and Emulsifiers, NorthAmerican Edition (1986), Allured Publishing Corp.; McCutcheon's,Functional Materials, North American Edition (1992), Allured PublishingCorp.; and U.S. Pat. No. 3,929,678 (Laughlin et al.). Other non-limitingexamples of suitable surfactants are included in U.S. Ser. No.61/1120,790.

Optional Ingredients

The optional ingredients may comprise active agents which may beselected from the group consisting of: personal cleansing and/orconditioning agents such as hair care agents, hair conditioning agents,skin care agents, and skin conditioning agents; laundry care and/orconditioning agents such a fabric care agents, fabric conditioningagents, fabric softening agents, fabric anti-wrinkling agents, fabriccare anti-static agents, fabric care stain removal agents, soil releaseagents, dispersing agents, suds suppressing agents, anti-foam agents,and fabric refreshing agents; hard surface care and/or conditioningagents such as liquid dishwashing agents, powder dishwashing agents,polishing agents, antimicrobial agents, perfume, bleaching agents (suchas oxygen bleaching agents, hydrogen peroxide, percarbonate bleachingagents, perborate bleaching agents, chlorine bleaching agents), bleachactivating agents, chelating agents, builders, brightening agents, dyetransfer-inhibiting agents, water-softening agents, water-hardeningagents, pH adjusting agents, acids, bases, medicinal agents, lotions,teeth whitening agents, tooth care agents, mouthwash agents, periodontalgum care agents, sunscreen agents, enzymes, flocculating agents,effervescent agents, preservatives, cosmetic agents, make-up removalagents, lathering agents, deposition aid agents, coacervate-formingagents, clays, thickening agents, latexes, silicas, drying agents,water-treatment agents, odor control agents, antiperspirant agents,cooling agents, warming agents, absorbent gel agents, anti-inflammatoryagents, dyes, pigments, edible agents, dietary agents, vitamins,minerals, and combinations thereof.

The optional ingredients may also include those materials approved foruse in cosmetics and that are described in reference books such as theCTF A Cosmetic Ingredient Handbook, Second Edition, The Cosmetic,Toiletries, and Perfume Association, Inc. 1988, 1992. Examples of suchoptional ingredients are disclosed in U.S. Ser. Nos. 12/361,634,10/392,422 filed Mar. 18, 2003; and US Publication 2003/0215522A1, datedNov. 20, 2003.

Release of Health Care Active

One or more health care actives and optional aesthetic agents can bereleased from the filament when the filament is exposed to a triggeringcondition. In one example, one or more health care actives may bereleased from the filament or a part of the filament when the filamentor the part of the filament loses its identity, in other words, losesits physical structure. For example, a filament loses its physicalstructure when the backbone material disintegrates, dissolves, melts orundergoes some other transformative step such that the filamentstructure is lost. In one example, the one or more health care activesare released from the filament when the filament's morphology changes.

In another example, one or more health care actives may be released fromthe filament or a part of the filament when the filament or the part ofthe filament alters its identity, in other words, alters its physicalstructure rather than loses its physical structure. For example, afilament alters its physical structure when the filament swells,shrinks, lengthens, and/or shortens, but retains its filament structure.

In one example, the filament may release a health care active upon thefilament being exposed to a triggering condition that results in therelease of the health care active, such as by causing the filament tolose or alter its identity as discussed above. Non-limiting examples oftriggering conditions include exposing the filament to solvent, exposingthe filament to heat, exposing the filament to cold, exposing thefilament to a force, such as a stretching force applied by a user usingthe filament, exposing the filament to a chemical reaction, exposing thefilament to a condition that results in a phase change, exposing thefilament to a pH change, exposing the filament to a pressure change,exposing the filament to a temperature change, exposing the filament tolight and/or certain wavelengths, exposing the filament to a differentionic strength, exposing the filament to a health care active oraesthetic agent released from another filament, and combinations thereof

In one embodiment the triggering condition is when the filament isexposed to a temperature from about 68° F. to about 212° F., in anotherembodiment from about 75° F. to about 140° F., in a further embodimentfrom about 80° F. to about 110° F., in yet another embodiment from about93° F. to about 106° F. In another embodiment, the triggering conditionis when the filament is exposed to a temperature from about 0° F. toabout 60° F., in another embodiment from about 15° F. to about 50° F.,and in yet another embodiment from about 25° F. to about 40° F. Inanother embodiment, the triggering condition is when the filament isexposed to water, saliva, whole blood, blood serum, mucus, perspiration,digestive fluids, tears, or combinations thereof. In another embodiment,the triggering condition is when the filament is exposed to a pH fromabout 2 to about 8, in another embodiment from about 2 to about 6, inanother embodiment from about 2 to about 5, and in yet anotherembodiment from about 2 to about 3. In one embodiment, the triggeringcondition is the pH of the duodenum which has a pH from about 5 to about7.

Coating Composition

The health care active(s) and/or aesthetic agent(s) can optionally bepresent, at least partially, as a coating composition. The coatingcomposition can be applied to the filament, nonwoven web, or thepersonal health care article. In certain embodiments, the coatingcomposition covers an outer surface of the filament or the nonwoven web.In another embodiment, the coating composition covers an outer surfaceof the personal health care article, putting the coating composition inposition to immediately contact the target surface (e.g. saliva in themouth) during use for the release of the health care active(s) and/oraesthetic agent(s).

In an embodiment the coating composition of the present invention maycomprise one or more health care actives as defined herein. In anotherembodiment, the coating composition of the present invention maycomprise one or more aesthetic agents as defined herein.

In an embodiment, the filament, nonwoven web, or personal health carearticle may comprise one or more health care actives which can be thesame or different from the health care active present in the coatingcomposition. In another embodiment, the filament, nonwoven web, orpersonal health care article can comprise a delayed delivery, anextended delivery health care active, and/or a targeted delivery healthcare active and the coating composition comprises an immediate deliveryhealth care active. In another embodiment, the filament, personal healthcare article, or nonwoven web can comprise one or more aesthetic agentswhich can be the same or different from the aesthetic agent in thecoating composition.

Process for Manufacture

The filaments, nonwoven web, and/or personal health care article can beprepared by the process comprising: (1) Preparing a processing mixture;(2) Forming filaments; (3) Optionally forming nonwoven webs; (4)Optionally forming a personal health care article; (5) Optionally asecond drying step; and (6) Optionally applying a coating composition.

Preparation of Processing Mixture

The filaments of the present invention are made from a processingmixture. The one or more backbone materials and optionally theextensional aid, plasticizer, and crosslinking agents are combined inthe presence of water to form the filament-forming mixture. Theprocessing mixture can be mixed by any suitable mixing system such thatthe filament-forming material(s) are sufficiently combined in thepresence of water. In certain embodiments, the backbone materialcompletely dissolves to make a solution. After the filament-formingmixture is made, the health care active(s) and optionally the aestheticagents, additional extensional aids, plasticizers, and crosslinkingagents can be added to form the processing mixture. In one embodiment,the filament-forming mixture is cooled to about room temperature (25°C.) before the health care actives are added and in another embodimentthe processing mixture is cooled to about room temperature (25° C.)before the filaments are formed. In one embodiment, the processingmixture is a melt comprising the filament forming materials, health careactives, and optionally the aesthetic agents, extensional aids,plasticizers, and crosslinking agents. The filament forming materials,health care actives, and optionally the aesthetic agents, extensionalaids, plasticizers, and crosslinking agents can be dissolved, suspended,or combinations thereof in the processing mixture.

The processing mixture of the present invention has a shear viscosity,as measured according to the Shear Viscosity Test Method describedhereafter. In one embodiment, the processing mixture has a shearviscosity of from about 1 pascal·seconds (Pa·s) to about 25 Pa·s, inanother embodiment from about 2 Pa·s to about 20 Pa·s, in yet anotherembodiment from about 3 Pa·s to about 10 Pa·s. This shear viscosity canbe achieved by adjusting the amount of water, the amount of the variousingredients dissolved or suspended therein, or both.

The processing mixture may be processed at any convenient temperature:in one embodiment at a temperature of from about 50° C. to about 100°C., in another embodiment, and in another embodiment from about 65° C.to about 95° C., and in another embodiment from about 70° C. to about90° C.

In one embodiment, the processing mixture comprises both volatile andnon-volatile components. The volatile components vaporize duringmeltblowing and are not present in the filament. Non-limiting examplesof volatile components can include water, ethanol, isopropanol,methanol, and combinations thereof. The non-volatile components do notvaporize during meltblowing and are present in the filament.Non-limiting examples of non-volatile ingredients can include healthcare actives, filament-forming materials, aesthetic agents, andcombinations thereof, as described herein. In one embodiment theprocessing mixture can comprise from about 20% to about 90% non-volatilecomponents, by weight of the processing mixture, in another embodimentfrom about 30% to about 85% non-volatile components, by weight of theprocessing mixture, in another embodiment from about 40% to about 75%non-volatile components, by weight of the processing mixture, and in yetanother embodiment from about 45% to about 60% non-volatile components,by weight of the processing mixture. In one embodiment the processingmixture can comprise from about 10% to about 80% volatile components, byweight of the processing mixture, in another embodiment from about 15%to about 70% volatile components, by weight of the processing mixture,in another embodiment from about 25% to about 60% volatile components,by weight of the processing mixture, and in yet another embodiment fromabout 40% to about 55% volatile components, by weight of the processingmixture.

The Capillary Number is a dimensionless number used to characterize thelikelihood of droplet breakup. The processing mixture may exhibit aCapillary Number. The processing mixture exhibits a Capillary Number offrom about 1 to about 50, in another embodiment from about 3 to about50, in yet another embodiment from about 5 to about 30, and in anotherembodiment from about 5 to about 20. A larger Capillary Number indicatesgreater fluid stability upon exiting the die. In the meltblowingprocess, the filaments need to have initial stability as they leave thedie in order to form a continuous filament.

The Capillary number is defined as follows:

${Ca} = \frac{V*\eta}{\sigma}$

V is the fluid velocity at the die exit (units of Length per Time)

η is the fluid viscosity at the conditions of the die (units of Mass perLength*Time)

σ is the surface tension of the fluid (units of mass per Time²)

When velocity, viscosity, and surface tension are expressed in a set ofconsistent units, the resulting Capillary Number will have no units ofits own; the individual units will cancel out.

The Capillary number is defined for the conditions at the exit of thedie. The fluid velocity is the average velocity of the processingmixture passing through the die opening. The average velocity is definedas follows:

$V = \frac{{Vol}^{\prime}}{Area}$

Vol′=volumetric flowrate (units of Length³ per Time)

Area=cross-sectional area of the die exit (units of Length²).

When the die opening is a circular hole, then the fluid velocity can bedefined as

$V = \frac{{Vol}^{\prime}}{\pi*R^{2}}$

R is the radius of the circular hole (units of length)

The fluid viscosity will depend on the temperature and may depend of theshear rate. The definition of a shear thinning fluid includes adependence on the shear rate. The surface tension will depend on themakeup of the fluid and the temperature of the fluid.

Forming Filaments

The filaments can be prepared from a processing mixture. After theprocessing mixture is prepared, the processing mixture is spun into oneor more filaments by any suitable spinning process. In one embodiment,the filaments can be made by meltblowing. In another embodiment, thefilaments can be made by fluid film fibrillation.

Electrostatic spinning is a commonly used method of producing sub-micronfilaments, but it is not the preferred method herein. In this method,typically, a polymer is dissolved in a solvent and placed in a chambersealed at one end with a small opening in a necked down portion at theother end. A high voltage potential is then applied between the polymersolution and a collector near the open end of the chamber. Theproduction rates of this process are very slow and filaments aretypically produced in small quantities. In an embodiment, the filamentsare not derived from electrostatic spinning.

Fluid Film Fibrillation

In one embodiment, the processing mixture is spun into one or morefilaments by fluid film fibrillation.

Fluid film fibrillation can comprise a pressurized gas stream flowingwithin a confined gas passage, comprising upstream converging wallsurfaces and downstream diverging wall surfaces into which theprocessing mixture is introduced to provide an extruded processingmixture film on a heated wall surface that is impinged by the gas streamflowing within the gas passage, effective to fibrillate the processingmixture film into filaments. “Converging” means that the cross-sectionalarea decreases in the direction of gas flow; and “diverging” means thatthe cross-sectional area increases in the direction of gas flow.

In one embodiment, the gas passage comprises a first, upstream sectioninto which the gas enters from a supply end, a transition region, and asecond, downstream section in which the gas flows to an exit end,wherein the transition region fluidly connects the first section to thesecond section, and the gas passage ends at the exit end of the secondsection. In a particular embodiment, the first section of the gaspassage has a monotonically decreasing cross-sectional area from thesupply end to the transition region, and the second section of the gaspassage has a monotonically increasing cross-sectional area from thetransition region to the exit end of the second section. At least oneflowing processing mixture stream is transmitted through at least onebounded passage which ends in at least one opening in at least one ofthe opposing heated walls. The processing mixture is in fluid form as itis introduced into the gas passage. Each processing mixture streamextrudes in the form of a film from each opening. Each extrudedprocessing mixture film joins with the gas stream and the processingmixture film is fibrillated to form filaments exiting from the exit endof the second section of the gas passage. For purposes herein,“monotonically decreasing cross-sectional area” means “strictlydecreasing cross-sectional area” from the upper inlet) end to the lowerend of the upstream nozzle section, and “monotonically increasingcross-sectional area” means “strictly increasing cross-sectional area”from the upper end to the exit end of the downstream section of thenozzle.

In a particular embodiment, each extruded processing mixture film joinswith the gas stream in the second section of the gas passage. Theintroduction of the processing mixture in the second section of thenozzle system on a diverging support wall (that may be heated) canfacilitate production of high quality filaments. In a furtherembodiment, the location where the extruded processing mixture filmjoins with the gas in the second, downstream section in order to producethe best quality filaments depends on the type of gas, the nozzlegeometry, including angles and transitions, and the pressure of the gas,and can be located in the upper half of the second section such as forlow gas pressure conditions, and can be located in the lower, downstreamhalf of the second section such as for high gas pressure conditions. Ina particular embodiment, only one processing mixture film forms on atleast one of the walls that may be heated, the gas pressure exceedsabout 10 pounds per square inch (psi), and each processing mixturepassage opening from which processing mixture film extrudes is locatedin a second, downstream half of the second section between thetransition region and the exit end of the second section. It has beenfound that the second half of the downstream second section can providea gas velocity region where fluid film fibrillation is accomplished veryefficiently, yielding high quality filaments.

For the purposes of this disclosure, the bounded passages forpressurized gas and processing mixture together will be referred as“nozzle” or “nozzle system”. The nozzle may have bounded passages in arectangular slot configurations or circular rounded configuration orelongated oval configuration or any configuration that would enableformation of one or more processing mixture film(s) to be impinged byone or more pressurized gas streams. In particular, for a rectangularslot configuration, one or more pressurized gas streams may flow througha bounded rectangular slot passage to impinge on the processing mixturefilm that forms on a rectangular wall surface to form the processingmixture filaments. In such rectangular slot configuration, the boundedpassage for one or more processing mixture may be circular rounded, orelongated oval, or rectangular slot, or any other shape.

An example of a circular nozzle 7 and a slot nozzle 20 for fluid filmfibrillation are further illustrated as cross-sectional views in FIGS.1A and 2A, respectively. These embodiments illustrate a nozzle 7, 20with orifice 7 a, which forms the filaments 17. The process morespecifically includes the steps of heating the processing mixture 2 andforming a fluid film 9 across an orifice 7 a. The processing mixturewill contain the water soluble polymer and any other desiredingredients. The processing mixture 2 is extruded through an orifice 7a, which in turn contains a fiberizing fluid stream 10 such that theprocessing mixture 2 extrudes as an elongated film 12 (illustrated inDetail A of FIGS. 1 and 2). The orifice 7 a may be part of a nozzle 7,20 and the nozzle 7, 20 may be optimized for process stability. Afiberizing fluid stream 10, such as a pressurized gas stream, is blownto form an elongated film 12. The fiberizing fluid stream 10 will thenprovide pressure on the inner surface (adjoining fiberizing fluidstream) of the elongated film 12. Thinned wall or weakened portions mayform in the elongated film 12 to more easily and controllably enable theformation of filaments including nanofilaments 17. The weakened portionsmay result from notches or projections located on the outer surface ofthe jet 10 or on the inner surface of the orifice 7 a. The weakenedportions may also result spontaneously due to local surface pressure onthe fluid film and/or fluid film flow rate differences across theperimeter of the film. The elongated film 12 is then subjected to afluid to form a multiplicity filaments 17. This fluid can be thepressurized gas stream (the fiberizing fluid stream) 10 or an entrainingfluid 14 or any fluid stream. The entraining fluid 14 is from transversejet 13. If advantageous, a nozzle 18 providing cooling or heating anadditional fluid stream 19, that can be used for heating or cooling, tothe formed filaments 17 may be used.

The processing mixture 2 is typically heated until it forms a liquid andflows easily. The processing mixture 2 may be at a temperature of fromabout 0° C. to about 150° C., in one embodiment from about 10° C. toabout 120° C., and in another embodiment from about 20° C. to about 100°C. The temperature of the polymer 2 depends on the processing mixturecomposition. The heated processing mixture 2 is at a pressure from about15 pounds per square inch absolute (psia) to about 220 psia, in anotherembodiment from about 20 psia to about 150 psia, and in yet anotherembodiment from about 25 psia to about 100 psia.

In some cases, the processing mixture film may coalesce immediatelyafter forming. In the case of the coalesced film, in one embodiment, itmay be preferred to have thinned walls or weakened portions in the filmto aid in the fibrillation. Non-limiting examples of the fiberizingfluid stream are gases such as nitrogen or in another embodiment air orany other fluid compatible (defined as reactive or inert) withprocessing mixture composition. The fiberizing fluid stream 10 can be ata temperature close to the temperature of the heated processing mixture2. The fiberizing fluid stream 10 temperature may be at a highertemperature than the heated processing mixture 2 to help in the flow ofthe processing mixture 2 and the formation of the fluid film 9.Alternatively, the fiberizing fluid stream 10 temperature can be belowthe heated processing mixture 2 temperature. In one embodiment, thefiberizing fluid stream temperature is about 100° C. above the heatedprocessing mixture 2, in another embodiment about 50° C. above theheated processing mixture 2, or just at temperature of the heatedprocessing mixture 2. The pressure of the fiberizing fluid stream 10 issufficient to fibrillate the processing mixture into filaments 17 and isabove the pressure of the heated processing mixture as it is extrudedout of the orifice 7 a.

The fiberizing fluid stream 10 may have a velocity of more than about200 meter per second at the location of film fibrillation. In oneembodiment, at the location of film fibrillation, the fiberizing fluidstream velocity will be more than about 300 meter per second, i.e.,transonic velocity; in another embodiment more than about 330 meter persecond, i.e., sonic velocity; and in yet another embodiment from about350 to about 800 meters per second (m/s), i.e., supersonic velocity. Thefiberizing fluid stream may pulsate or may be a steady flow.

The processing mixture 2 throughput will primarily depend upon thespecific processing mixture used, the nozzle design, and the temperatureand pressure of the processing mixture. The processing mixture 2throughput will be more than about 1 gram per minute per orifice, forexample in a circular nozzle 7 illustrated in FIG. 1A. In oneembodiment, the processing mixture throughput will be more than about 10gram per minute per orifice and in another embodiment greater than about20 gram per minute per orifice, and in yet another embodiment greaterthan about 30 gram per minute per orifice. In an embodiment with theslot nozzle 20, such as the one illustrated in the FIG. 2A, theprocessing mixture throughput will be more than about 0.5 kilogram perhour per meter width of the slot nozzle. In another slot nozzleembodiment, the processing mixture throughput will be more than about 5kilogram per hour per meter width of the slot nozzle, and in anotherslot nozzle embodiment, the processing mixture throughput will be morethan about 10 kilogram per hour per meter width of the slot nozzle, andin yet another slot nozzle embodiment, the processing mixture throughputwill be more than about 20 kilogram per hour per meter width of the slotnozzle. In certain embodiments of the slot nozzle, the processingmixture throughput may exceed about 40 kilogram per hour per meter widthof the slot nozzle. There will likely be several orifices 7 a operatingat one time which further increases the total production throughput. Thethroughput, along with pressure, temperature, and velocity, are measuredat the orifice 7 a for both circular 7 and slot nozzles 20.

The fibrillation of the filaments may occur before the filaments andfluid exit the orifice. Once the elongated film exits the orifice, thefilaments are formed. Commonly, the formation of filaments occursimmediately upon exiting the orifice. One or more fluid streams may beused to form the multiplicity of filaments. The fiberizing fluid stream10 can be the fluid stream adjoining the processing mixture film, anentraining fluid, or any other fluid stream. Optionally, an entrainingfluid 14 can be used to induce a pulsating or fluctuating pressure fieldto help in forming a multiplicity of filaments 17. Non-limiting examplesof the entraining fluid 14 are pressurized gas stream such as compressedair, nitrogen, oxygen, or any other fluid compatible (defined asreactive or inert) with the processing mixture composition. As shown inFIGS. 1 and 2, the entraining fluid 14 may be provided by a transversejet 13 which is located to direct the flow of entraining fluid 14 overand around the elongated film 12 and filament 17 forming region. Theentraining fluid 14 can have a low velocity or a high velocity. Theentertaining fluid with a high velocity can have a velocity near sonicspeed (i.e. about 343.2 m/s) or supersonic speeds (i.e. greater thanabout 343.2 m/s). An entraining fluid with a low velocity will typicallyhave a velocity of from about 1 to about 100 m/s and in anotherembodiment from about 3 to about 50 m/s. It is desirable to have lowturbulence in the entraining fluid stream 14 to minimizefilament-to-filament entanglements, which usually occur due to highturbulence present in the fluid stream. The temperature of theentraining fluid 14 can be the same as the above fiberizing fluid stream10, or a higher temperature to aid drying of filaments, and ranges fromabout 80° C. to 300° C. and in another embodiment from about 100° C. toabout 250° C. The moisture content or the relative humidity of theentraining fluid 14 when used as drying fluid is very low, generallyless than 20%, in another embodiment less than 10%, in anotherembodiment less than 5%, and in yet another embodiment less than 1%.

Optionally, an additional fluid stream 19, that can be used for heatingor drying, can also be used. The additional fluid stream 19 may be apressurized gas stream such as compressed air, nitrogen, oxygen, or anyother fluid compatible (defined as reactive or inert) with theprocessing mixture composition. This additional fluid stream 19 islocated to direct fluid into the filaments 17 to dry the filaments. Itis desirable to have low turbulence in the additional fluid stream 19 tominimize filament-to-filament entanglements, which usually occur due tohigh turbulence present in the fluid stream. If the additional fluid isused as a heating or drying fluid, it is at a temperature of from about80° C. to 300° C. and typically from about 100° C. to about 250° C. Themoisture content or the relative humidity of the additional fluid streamwhen used as drying fluid is very low, generally less than 20%, in oneembodiment less than 10%, in yet another embodimentless than 5%, and inyet another embodiment less than 1%. The additional fluid stream 19 mayform a “curtain” or “shroud” around the filaments exiting from thenozzle. Any fluid stream may contribute to the fiberization of theprocessing mixture and can thus generally be called fiberizing fluidstreams.

The filaments may be partially or completely dried in flight to thecollector by any or combination of the fiberizing fluid streams—thefiberizing fluid stream 10, the entraining fluid 14, or the additionalfluid stream 19. Alternatively, the fiberizing fluid stream 10 or thefirst pressurized gas stream may be the only fluid stream used forfibrillation and partially or completely drying the processing mixturefilaments. In such instance, the drying fluid stream is continuation ofthe fiberizing fluid stream 10. Alternatively, the fiberizing fluidstream 10 and the second entraining fluid stream 14 may the fluidstreams used for fiberizing and drying, respectively. Alternatively, thefiberizing fluid stream 10 and the additional fluid stream 19 may beused for fiberizing and drying, respectively. In a particularembodiment, the additional fluid stream 19 may be adjacent to thefiberizing fluid stream 10. In another embodiment the additional fluidstream 19 may be at an angle to the fiberizing fluid stream 10 afterexiting the nozzle. The angle of the additional fluid stream 19 mayrange from about 0° (parallel) to 90° (perpendicular) to the fiberizingfluid stream 10 as it exits the nozzle. The additional fluid stream 19can have a low velocity or a high velocity. The additional fluid streamwith a low velocity can have a velocity of from about 1 m/s to about 100m/s and in one embodiment from about 3 m/s to about 50 m/s. Theadditional fluid stream with a high velocity can have a velocity ofgreater than about 300 m/s, in another embodiment greater than about 330m/s, and in yet another embodiment from about 350 m/s to about 700 m/s.One or more drying fluid stream(s) either completely or partially drythe in-flight filaments fibrillated from the processing mixture film. Ina particular embodiment, one or more drying fluid stream(s) canpartially dry the filaments or dry the filaments to the desired finalmoisture content. In one embodiment, the filaments are dried to a finalmoisture content of less than about 20%, in another embodiment less thanabout 15%, in another embodiment less than about 10%, in anotherembodiment less than about 7%, in yet another embodiment less than about5%, in another embodiment less than about 3%.

Meltblowing

In one embodiment, the processing mixture is spun into one or morefilaments by meltblowing. For example, the processing mixture may bepumped from an extruder to a meltblown spinnerette. Upon exiting one ormore of the filament-forming holes in the spinnerette, the processingmixture is attenuated with air to create one or more filaments.

In one embodiment, the filaments according to the present invention areproduced by using a small-scale apparatus 26, a schematic representationof which is shown in FIGS. 3 and 4. In this nonlimiting embodiment,demonstrated in FIG. 1, the processing mixture is in tank 30 and thengoes through pipe 36 to a pump 32 (for example a Zenith®, type PEP IIpump having a capacity of 5.0 cubic centimeters per revolution (cc/rev),manufactured by Parker Hannifin Corporation, Zenith Pumps division, ofSanford, N.C., USA). The pump then pumps the processing mixture througha pipe 36 to a die 34. The processing mixture material flows to a die iscontrolled by adjusting the number of revolutions per minute (rpm) ofthe pump. The die 34 as shown in FIG. 4 has two or more rows of circularextrusion nozzles 38 spaced from one another at a pitch P of about 1.524millimeters (about 0.060 inches). The nozzles 38 have individual innerdiameters of about 0.305 millimeters (about 0.012 inches) and individualoutside diameters of about 0.813 millimeters (about 0.032 inches). Eachindividual nozzle 38 is encircled by an annular and divergently flaredorifice 40 to supply attenuation air to each individual nozzle 38. Theprocessing mixture 30 that is extruded through the nozzles 38 issurrounded and attenuated by generally cylindrical, humidified airstreams supplied through the orifices 40 encircling the nozzles 38 toproduce the filaments 42. Attenuation air is provided by heatingcompressed air from a source by an electrical-resistance heater, forexample, a heater manufactured by Chromalox, Division of EmersonElectric, of Pittsburgh, Pa., USA. An appropriate quantity of steam isadded to the attenuation air to saturate or nearly saturate the heatedair at the conditions in the electrically heated, thermostaticallycontrolled delivery pipe. Condensate is removed in an electricallyheated, thermostatically controlled, separator.

The filaments may then be partially dried or dried to the desired finalmoisture content to remove any remaining volatile components used forprocessing. In one embodiment, the filaments are dried immediately afterthey are extruded. The filaments can be dried by a drying air streamhaving a temperature of from about 149° C. (about 300° F.) to about 315°C. (about 600° F.), in another embodiment from about 163° C. (about 325°F.) to about 260° C. (about 500° F.), and in a further embodiment fromabout 177° C. (about 350° F.) to about 232° C. (about 450° F.). In oneembodiment the filaments are dried by the air stream for less than about30 seconds, in another embodiment for less than about 15 seconds, inanother embodiment less than about 5 seconds, in yet another embodimentless than about 1 second, and in another embodiment less than about 0.5seconds. In one embodiment, the air stream can be heated by anelectrical resistance heater supplied through drying nozzles dischargedat an angle of about 90° relative to the general orientation of thefilaments being extruded.

The filaments can be partially dry or dried to the desired finalmoisture content. In one embodiment, the filaments are dried to a finalmoisture content of less than about 20%, in another embodiment less thanabout 15%, in another embodiment less than about 10%, in anotherembodiment less than about 7%, in yet another embodiment less than about5%, in another embodiment less than about 3%.

Forming and Processing a Nonwoven Web

The process of the present invention may optionally comprise a step ofcollecting a plurality of the filaments to form a nonwoven web.

In one embodiment, the partially dry or dried to desired moisturecontent filaments are laid down on a collector to form a web. Thecollector is typically a conveyor belt or a drum. The collector can beporous and vacuum may be applied to provide suction to aid filament laydown on the collector. The distance from the orifice to the collectordistance, commonly called die-to-collector distance (DCD), can beoptimized for desired nonwoven web properties. It may be desired toutilize more than one DCD used in a nonwoven web, to change the DCDduring production, or to have different beams with different DCDs. Itmay be desirable to form a nonwoven web with different uniformities bychanging the DCD. If the DCD is such that filaments are not sufficientlydried before depositing on the collector, the wet or insufficiently dryfilaments may coalesce to form blobs or bundles that may not bedesirable and would constitute as defects. Alternatively, it may bedesirable for a personal health care article to have some or allfilaments coalesce completely or partially, e.g., to have structuralintegrity. If the DCD is large and such that filaments are sufficientlydried, the filaments may entangle or stick to one another, but notcoalesce, to form bundles or ropes that may not be desirable. Therefore,depending on the desired personal health care article, the DCD may beset to form nonwoven web with desirable uniformity and sufficientdryness. Alternatively, the nonwoven webs of desirable uniformity may befurther dried to obtain moisture content desired in the Article.

Additionally, the die-to-collector distance may be altered along withthe vacuum underneath the collector to obtain desired density of theweb. Generally, the shorter DCD and/or higher vacuum provides densernonwoven webs relative to the larger DCD. At shorter DCD and/or highervacuum, the filaments tend to be “forced” together tightly by thefiberizing fluid jet and/or vacuum suction, while at the larger DCDand/or lower vacuum, the filaments stay fluffy and thus lower density.Therefore, depending on the desired Article density, it may be desirableto optimize DCD and/or vacuum for uniformity, dryness, and density.

The nonwoven webs of the processing mixture may be formed a desiredshape or shapes including, but not limited to (i) depositing thenonwoven web to specially designed molds comprising a non-interactingand non-stick surface including Teflon, metal, HDPE, polycarbonate,neoprene, rubber, LDPE, glass and the like; (ii) depositing the nonwovenweb into cavities imprinted in dry granular starch contained in ashallow tray, otherwise known as starch moulding forming technique; and(iii) depositing the nonwoven web onto a continuous belt or screencomprising any non-interacting or non-stick material Teflon, metal,HDPE, polycarbonate, neoprene, rubber, LDPE, glass and the like whichmay be later stamped, cut, embossed or stored on a roll.

Optionally Forming a Personal Health Care Article

In an embodiment, the nonwoven web of the present invention may then bepost-processed by subjecting the filament or nonwoven web to apost-processing operation. Nonlimiting examples of post-processingoperations include curing, embossing, thermal bonding, humidifying,perfing, calendering, printing, differential densifying, tuftdeformation generation, and other known post-processing operations.

The nonwoven webs and/or filaments may be formed into a desired shape orshapes to form a personal health care article. This includes, but is notlimited to (i) depositing the nonwoven web and/or filaments intospecially designed molds comprising a non-interacting and non-sticksurface including Teflon™, metal, HDPE, polycarbonate, neoprene, rubber,LDPE, glass and the like; (ii) depositing the nonwoven web and/orfilaments into cavities imprinted in dry granular starch contained in ashallow tray, otherwise known as starch molding forming technique; and(iii) depositing the nonwoven web and/or filaments onto a continuousbelt or screen comprising any non-interacting or non-stick materialTeflon™, metal, HDPE, polycarbonate, neoprene, rubber, LDPE, glass andthe like which may be later stamped, cut, embossed or stored on a roll.

In an embodiment, the personal health care article of the presentinvention can be a flat article in the form of a pad, strip, tape,tablet, cylinder, sphere, or rectangular prism.

Optionally Drying the Nonwoven Web and/or the Filaments

The nonwoven webs and/or filaments can be dried if they are not at thedesired final moisture level. This drying process may be accomplished byany suitable means including, but not limited to (a) multi-stage inlinedryers using convection or through-air drying; (b) drying room(s)including rooms with controlled temperature and pressure or atmosphericconditions; (c) ovens including non-convection or convection ovens withcontrolled temperature and optionally humidity; (d) truck/tray dryers,impingement ovens; (e) rotary ovens/dryers; (f) inline roasters; (g)rapid high heat transfer ovens and dryers; (h) dual plenum roasters, and(i) conveyor dryers.

Optionally Applying a Coating Composition

A coating composition may be imparted during any of the above describedprocessing steps. The coating composition can be applied to thefilament, nonwoven web, and/or the personal health care article. Thecoating composition can be applied by any suitable mechanical, chemical,or other means to produce a coating composition comprising the healthcare actives or aesthetic agents.

The coating composition can be applied by spraying, dusting, sprinkling,coating, surface-printing (e.g., in the shape of a desired adornment,decoration, or pattern), pouring on, injecting into the interior,dipping, or by any other suitable means, such as by use of a depositor,sifter, or powder bed. The coating composition can be applied overportions or entire regions of the filament, nonwoven, or personal healthcare article, and can be applied in a manner to adorn, decorate, form alogo, design, etc.

When the coating compositions are applied to the filaments, nonwovenwebs, or personal health care articles as a fluid the fluid can beapplied as a spray, a gel, or a cream coating.

When the coating compositions are a powder, the powder can be applied byallowing the filaments, nonwoven webs, or personal health care articleto have a tacky surface by drying the filament or nonwoven web to aspecific moisture content before applying the powder to facilitate theadherence of the coating composition. In another embodiment, a surfaceof the filament, nonwoven web, or personal health care article isbrushed with a cotton swab dipped in distilled water and then the powdercan be applied. In another embodiment, the filament or nonwoven web isplaced in a bag, tray, belt, or drum containing or otherwise exposed tothe powder and agitated, rolled, brushed, vibrated or shaken to applyand distribute the powder, either in a batch or continuous productionmanner Other powder application methods may include powder sifters,electrostatic coating, tribo charging, fluidized beds, powder coatingguns, corona guns, tumblers, electrostatic fluidized beds, electrostaticmagnetic brushes, and/or powder spray booths.

When the coating composition comprises two or more health care activesand/or aesthetic agents the two or more health care actives and/oraesthetic agents can be blended or otherwise combined together within asingle coating composition or they may be applied via a multiplicity ofdifferent coating compositions that may or may not be in contact withone another (applied as layers or to differing regions of the filament,nonwoven web, or personal health care article and combinations thereof).The two or more health care actives and/or aesthetic agents can also beapplied to different regions of the filament, nonwoven web, or personalhealth care article. For instance, in one embodiment the personal healthcare article is a pad and a first coating composition is applied to oneside and a second coating composition is applied to the second pad andthe first coating composition and the second coating composition aredifferent.

In certain embodiments, the personal health care article contains acoating composition that can be situated below the surface of thepersonal health care article. For instance, the personal health carearticle could contain dimples and the coating composition could belocated within the dimples of the personal health care article. Inanother embodiment, the coating composition may permeate the personalhealth care article in whole or in part to form the personal health carearticle.

In another embodiment, the personal health care article comprises afirst nonwoven web and a second nonwoven web, and the coatingcomposition is situated between the first nonwoven web and the secondnonwoven web. In this nonlimiting embodiment, the two nonwoven webs canbe joined together (e.g., via sealing the adjoining surfaces or edgeswith a thin layer of water and/or plasticizer so as to not substantiallydissolve the nonwoven web and applied pressure to induce adhesion).Alternatively, in certain embodiments, the coating composition may be onone nonwoven web which is folded over to form a pouch, encasing thecoating composition.

Test Methods Diameter Test Method

The diameter of the filaments and the diameter of the filaments in asample of a nonwoven web or personal health care article is determinedby using a Scanning Electron Microscope (SEM) or an Optical Microscopeand an image analysis software. A magnification of 200 to 10,000 timesis chosen such that the filaments are suitably enlarged for measurement.When using the SEM, the samples are sputtered with gold or a palladiumcompound to avoid electric charging and vibrations of the filaments inthe electron beam. A manual procedure for determining the filamentdiameters is used from the image (on monitor screen) taken with the SEMor the optical microscope. Using a mouse and a cursor tool, the edge ofa randomly selected filament is sought and then measured across itswidth (i.e., perpendicular to filament direction at that point) to theother edge of the filament. A scaled and calibrated image analysis toolprovides the scaling to get actual reading in μm. Several filaments arethus randomly selected across the sample of the web using the SEM or theoptical microscope. At least two specimens from the web (or web inside aproduct) are cut and tested in this manner Altogether at least 100 suchmeasurements are made and then all data are recorded for statisticanalysis. The recorded data are used to calculate average (mean) of thefilament diameters, standard deviation of the filament diameters, andmedian of the filament diameters.

Another useful statistic is the calculation of the amount of thepopulation of filaments that are below a certain upper limit. Suitablenon-limiting upper limits for the present invention are about 1 μm, inanother embodiment about 3 μm, in another embodiment about 5 μm, inanother embodiment about 10 μm, and in another embodiment about 100 μm.To determine this statistic, the software is programmed to count howmany results of the filament diameters are below an upper limit and thatcount (divided by total number of data and multiplied by 100%) isreported in percent as percent below the upper limit, such as percentbelow 1 micrometer diameter or %-submicron, for example. The measureddiameter (in microns) of an individual circular filament is denoted asd_(i).

In case the filaments have non-circular cross-sections, the measurementof the filament diameter is determined as and set equal to the hydraulicdiameter which is four times the cross-sectional area of the filamentdivided by the perimeter of the cross of the filament (outer perimeterin case of hollow filaments). The number-average diameter, alternativelyaverage diameter is calculated as:

$d_{num} = \frac{\sum\limits_{i = 1}^{n}\; d_{i}}{n}$

Moisture Content Test Method

The moisture content present in the filament of the present invention ismeasured using the following Moisture Content Test Method.

A filament or nonwowen web or portion thereof (hereinafter “sample”) isplaced in a conditioned room at a temperature of 23° C. and a relativehumidity of 50% until the weight of the sample reaches equilibrium(i.e., no further weight change is detected within a 5 minute period).Record this weight as the “equilibrium weight.” Next, place the samplein an oven at 70° C. for 24 hours to dry the sample. After the 24 hours,immediately weigh the sample and record the weight of the sample at its“bone dry” weight.

The water content of the sample is calculated as follows:% Moisture in Sample=(Equilibrium weight−Bone dry weight)/Bone dryweight

Thickness Method

The thickness of the personal health care article is taken as themaximum distance in the shortest direction and is measured inmillimetres (mm). The thickness is calculated as the length obtainedusing a micrometer or thickness gage, such as the Mitutoyo CorporationDigital Disk Stand Micrometer Model Number IDS-1012E (MitutoyoCorporation, 965 Corporate Blvd, Aurora, Ill., USA 60504). Themicrometer has a 1 inch diameter platen weighing about 32 grams (g),which measures thickness at an application pressure of about 0.009 psi(6.32 g/cm²).

The thickness of the personal health care article is measured by raisingthe platen, placing a section of the sample on the stand beneath theplaten, carefully lowering the platen to contact the sample, releasingthe platen, and measuring the thickness of the sample in millimeters onthe digital readout. The sample should be fully extended to all edges ofthe platen to make sure thickness is measured at 0.009 psi (6.32 g/cm²),except for the case of more rigid samples which are not flat. For morerigid samples which are not completely flat, a flat edge of the sampleis measured using only one portion of the platen impinging on the flatportion of the sample. In the case of cylindrical, spherical, or otherobjects with more of a third dimension versus a pad or strip, thethickness is taken as the maximum distance of the shortest dimension,i.e., the diameter of a sphere or cylinder for instance, and thethickness ranges are the same as described above.

Shear Viscosity Test Method

The shear viscosity of the processing mixture of the present inventionis measured using a capillary rheometer, Goettfert Rheograph 6000,manufactured by Goettfert USA of Rock Hill S.C., USA. The measurementsare conducted using a capillary die having a diameter D of 1.0 mm and alength L of 30 mm (i.e., L/D=30). The die is attached to the lower endof the rheometer's 20 mm barrel, which is held at a die test temperatureof 75° C. A sample of the processing mixture, weighing 60 g andpreheated to die test temperature (75° C.), is loaded into the barrelsection of the rheometer. Any entrapped air is removed from the sample.Push the sample from the barrel through the capillary die at a set ofchosen rates 1,000-10,000 seconds⁻¹. An apparent shear viscosity can becalculated with the rheometer's software from the pressure drop thesample experiences as it goes from the barrel through the capillary dieand the flow rate of the sample through the capillary die. The log(apparent shear viscosity) can be plotted against log (shear rate) andthe plot can be fitted by the power law, according to the formulaη=Kγ^(n-1), wherein K is the material's viscosity constant, n is thematerial's thinning index and γ is the shear rate. The reported apparentshear viscosity of the composition herein is calculated from aninterpolation to a shear rate of 3,000 sec⁻¹ using the power lawrelation.

Filament Composition Test Method

In order to prepare filaments for filament composition measurement, thecoating composition, if any, must be removed from the filaments. Thefilaments are then air dried at 73° F. until the filaments comprise lessthan 10% moisture. A chemical analysis of the conditioned filaments isthen completed to determine the compositional make-up of the filamentswith respect to the backbone materials and the active agents and thelevel of the backbone materials and active agents present in thefilaments.

EXAMPLES

The following examples further describe and demonstrate embodimentswithin the scope of the present invention. The examples are given solelyfor the purpose of illustration and are not to be construed aslimitations of the present invention, as many variations thereof arepossible without departing from the spirit and scope of the invention.All exemplified amounts are concentrations by weight of the totalcomposition, i.e., wt/wt percentages, unless otherwise specified.

Example 1

The following personal health care article can be prepared in accordancewith the present invention:

Component Wt % of Processing Mixture Ethylex 2035 Starch¹ 32.13%Naproxen-Na  9.64% Polyox WSR N-60K PEO²  0.07% Distilled Water q.s.Total   100% ¹Ethylex ™ 2035 Starch available from Tate & Lyle (London,United Kingdom) ²Polyox ® WSR N-60K PEO available from Dow (Midland,Michigan)

Example 1 can be made by the following procedure. The distilled water isput into an appropriately sized and cleaned vessel and then is stirredat 100-300 revolutions per minute (rpm) and heated to 80° C. TheEthylex™ 2035 and the Polyox® are weighed into a suitable container andare slowly added to the heated distilled water in small increments usinga spatula. The Ethylex™ 2035 and Polyox® are added to the distilledwater and continuously stirred at 80° C. until the Ethylex™ 2035 andPolyox® are dissolved resulting in the filament-forming mixture.

The filament-forming mixture is cooled to 25° C., then the naproxen-Nais slowly added to the filament-forming mixture and continuously stirreduntil the naproxen-Na is dissolved. The filament-forming mixture withthe dissolved naproxen-Na is the processing mixture.

This processing mixture is made into filaments by meltblowing asdescribed herein. Then, nonwoven webs are formed. The nonwoven webs willhave a basis weight of about 600 g/m² and are then cut into personalhealth care articles with a surface area of about 8 cm². A mammal inneed of a health benefit or a treatment for a health condition, canconsume two personal health care articles, containing a total of about220 mg naproxen-Na, by placing the articles directly into his or hermouth, allowing the personal health care article to disintegrate, andthen swallowing the disintegrated article.

In the foregoing example, naproxen-Na can be replaced with an equivalentamount of phenylephrine HCl, diphenhydramine HCl, ranitidine HCl,vitamin B9, and combinations thereof.

Example 2

The following personal health care article can be prepared in accordancewith the present invention:

Component Wt % of Processing Mixture Celvol 523 Polyvinyl Alcohol³19.56% Doxylamine Succinate  4.46% FD&C Blue #1  0.09% Sucrose  2.13%Distilled Water q.s. Total   100% ³Celvol ® 523 available from SekisuiCorporation (Dallas, Texas)

Example 2 can be made by the following procedure. The distilled water isput into an appropriately sized and cleaned vessel and then is stirredat 100-300 rpm and heated to 80° C. The Celvol® 523 is weighed into asuitable container and is slowly added to the heated distilled water insmall increments using a spatula. The Celvol® 523 is gradually added tothe distilled water and continuously stirred at 80° C. until the Celvol®is dissolved resulting in the filament-forming mixture.

Then, the sucrose and blue #1 are slowly added to the filament-formingmixture. The temperature of the filament-forming mixture with thesucrose and blue #1 is maintained at 80° C. and continuously stirreduntil the sucrose and blue #1 are dissolved. The filament-formingmixture with sucrose and blue #1 is allowed to cool to 25° C., then thedoxylamine succinate is slowly added while continuously stirring untilthe doxylamine succinate is dissolved to form the processing mixture.

This processing mixture is made into filaments by meltblowing asdescribed herein. Then, nonwoven webs are formed and have a basis weightof about 92 g/m² and then cut into personal health care articles with asurface area of about 4 cm². A mammal in need of a health benefit or atreatment for a health condition, can consume one personal health carearticle, containing about 6.25 mg doxylamine succinate, by placing thearticles directly into his or her mouth, allowing the personal healthcare article to disintegrate, and then swallowing the disintegratedarticle.

Example 3

The following personal health care article can be prepared in accordancewith the present invention:

Component Wt % of Processing Mixture Celvol 523 Polyvinyl Alcohol 12.64%Naproxen-Na 13.83% Doxylamine Succinate  0.39% Vanilla  1.10%Dextromethorphan HBr  0.94% Propylene Glycol 10.11% Distilled Water q.s.Total   100%

Example 3 can be made by the following procedure. The propylene glycolis put into an appropriately sized and cleaned vessel and then isstirred at 100-300 rpm at 25° C. The dextromethorphan HBr is weighedinto a suitable container and is slowly added to the propylene glycol insmall increments using a spatula. The propylene glycol anddextromethorphan HBr are stirred continuously at 100-300 rpm at 25° C.until the dextromethorphan HBr dissolves. The propyleneglycol/dextromethorphan HBr mixture is set aside.

In a separate vessel, the distilled water is put into an appropriatelysized and cleaned vessel and then is stirred at 100-300 rpm and heatedto 80° C. The Celvol® 523 is weighed into a suitable container and isslowly added to the heated distilled water in small increments using aspatula. The Celvol® 523 is gradually added to the distilled water andcontinuously stirred at 80° C. until the Celvol® is dissolved resultingin the filament-forming mixture.

The filament-forming mixture is allowed to cool to 25° C., then thenaproxen-Na/doxylamine succinate/vanilla mixture is slowly added to thefilament-forming mixture and continuously stirred until the naproxen-Na,doxylamine succinate, and vanilla are dissolved. Then, the propyleneglycol/dextromethorphan HBr mixture is added to the polyvinylalcohol/naproxen-Na/doxylamine succinate/vanilla mixture at 25° C. Thetwo mixtures are continuously stirred until the two mixtures have beenuniformly blended to form the processing mixture.

This processing mixture is made into filaments by meltblowing asdescribed herein. Then, nonwoven webs are formed that have a basisweight of about 390 g/m² and then cut into articles with a surface areaof about 8 cm². A mammal in need of a health benefit or a treatment fora health condition, can consume two personal health care articles,containing a total of about 220 mg naproxen-Na, about 6.25 mg doxylaminesuccinate, and about 15 mg dextromethorphan, by placing the articlesdirectly into his or her mouth, allowing the personal health carearticle to disintegrate, and then swallowing the disintegrated article.

Example 4

The following personal health care article can be prepared in accordancewith the present invention:

Component Wt % of Processing Mixture Ethylex 2035 Starch  4.34% Celvol523 Polyvinyl Alcohol 12.49% Naproxen-Na 19.54% Vanilla  0.54% FD&C blue#1  0.11% Sucrose  1.63% Distilled Water q.s. Total   100%

Example 4 can be made by the following procedure. The distilled water isput into an appropriately sized and cleaned vessel and then is stirredat 100-300 rpm and is heated to 80° C. The Celvol® 523 is weighed into asuitable container and is slowly added to the heated distilled water insmall increments using a spatula while the distilled water is stirredcontinuously and forming visible lumps is avoided. The mixing speed iscontinuously adjusted to minimize foam formation. Once the Celvol® 523is dissolved the Ethylex™ 2035 is weighed into a suitable container andis slowly added to the distilled water and Celvol® 523 mixture, in smallincrements using a spatula. The Celvol® 523 and Ethylex™ are added tothe distilled water and continuously stirred at 80° C. until the Celvol®and Ethylex™ are dissolved resulting in the filament-forming mixture.

Then the naproxen-Na, vanilla, blue #1, and sucrose are slowly added tothe filament-forming mixture and continuously stirred at 80° C. untilthe naproxen-Na, vanilla, blue #1, and sucrose are dissolved to form theprocessing mixture.

This processing mixture is made into filaments by meltblowing asdescribed herein. Then, nonwoven webs are formed with a basis weight ofabout 272 g/m² and then cut into personal health care articles with asurface area of about 8 cm². A mammal in need of a health benefit or atreatment for a health condition, can consume two personal health carearticles, containing a total of 220 mg naproxen-Na, by placing thearticles directly into his or her mouth, allowing the personal healthcare article to disintegrate, and then swallowing the disintegratedarticle.

In the foregoing example, naproxen-Na can be replaced with an equivalentamount of phenylephrine HCl, diphenhydramine HCl, ranitidine HCl,vitamin B9, and combinations thereof.

Example 5

The following personal health care article can be prepared in accordancewith the present invention:

Component Wt % of Processing Mixture Celvol 523 Polyvinyl Alcohol 13.53%Naproxen-Na 17.65% Distilled Water q.s. Total   100%

Example 5 can be made by the following procedure. The distilled water isput into an appropriately sized and cleaned vessel and then is stirredat 100-300 rpm and heated to 80° C. The Celvol® 523 is weighed into asuitable container and is slowly added to the heated distilled water insmall increments using a spatula. The Celvol® 523 is gradually added tothe distilled water and continuously stirred at 80° C. until the Celvol®is dissolved resulting in the filament-forming mixture.

The filament-forming mixture is allowed to cool to 25° C. and then thenaproxen-Na is slowly added and stirred continuously until thenaproxen-Na is dissolved resulting in the processing mixture.

The processing mixture is made into filaments by meltblowing asdescribed herein. Then, nonwoven webs are formed and have a basis weightof about 243 g/m² and then cut into personal health care articles with asurface area of about 8 cm². A mammal in need of a health benefit or atreatment for a health condition, can consume two personal health carearticles, containing about 220 mg of naproxen-Na, by placing thearticles directly into his or her mouth, allowing the personal healthcare article to disintegrate, and then swallowing the disintegratedarticle. Alternatively two personal health care articles can be placedinto 8 ounces of water, stirred until dissolved, and then drank by amammal in need to deliver about 220 mg of naproxen-Na.

Example 6

The following personal health care article can be prepared in accordancewith the present invention:

Component Wt % of Processing Mixture Celvol 523 Polyvinyl Alcohol 13.53%Naproxen-Na 17.65% Distilled Water q.s. Total   100%

Example 6 can be made according to the procedure in Example 5 exceptafter the nonwoven webs are cut into personal health care articles thesurface of the personal health care article is lightly brushed withdistilled water Immediately following, 120 mg of pseudoephedrine HCl isapplied to the wetted surface. Then personal health care article isformed by allowing the coating is to dry at 25° C. for 16 hours in adesiccator that is protected from light.

A mammal in need of a health benefit or a treatment for a healthcondition, can consume one personal health care article, containingabout 220 mg of naproxen-Na and about 120 mg of pseudoephedrine, byplacing the article directly into his or her mouth, allowing thepersonal health care article to disintegrate, and then swallowing thedisintegrated article.

Example 7

The following personal health care article can be prepared in accordancewith the present invention:

Component Wt % of Processing Mixture Isomalt (Smart Sweet ™   67%Granules)⁴ Retail Cold & Flu Product⁵ 7.58% (Vicks ® NyQuil ® Cold & Flu(Cherry Flavor)) Distilled Water q.s. Total  100% ⁴Smart Sweet ™Granules are available from Global Sweet Polyols (Rehoboth,Massachusetts) ⁵Vicks ® NyQuil ® Less Drowsy Cold & Flu (Cherry Flavor)is available from The Procter & Gamble Company (Cincinnati, Ohio)

Example 7 can be made by the following procedure. The distilled water isput into an appropriately sized and cleaned vessel and then is stirredat 100-300 rpm and heated to 25° C. The retail cold and flu product ismeasured and slowly added to the distilled water.

In a separate container, the isomalt granules are weighed into asuitable container and are slowly heated to 150° C. until the isomaltgranules are melted. Then, the retail cold and flu/distilled watermixture is gradually added to the melted isomalt and continuouslystirred at 150° C. until the retail cold and flu/distilled water mixtureis fully incorporated into the melted isomal to form the processingmixture.

The processing mixture is made into filaments by fluid film fibrillationas described herein. Then, nonwoven webs are formed and then thenonwoven webs are cut into personal health care articles with a surfacearea of about 8 cm².

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An oral care article comprising: a. a firstnonwoven web and a second nonwoven web, the first and second nonwovenwebs comprising: i. from about 10% to about 80%, by weight of thenonwoven webs, of one or more backbone materials, and ii. less than 10%,by weight of the nonwoven webs, of water; and c. a coating compositionsealed between the first and second nonwoven webs, the coatingcomposition comprising fluoride; wherein the coating composition isreleasable from the oral care article upon exposure to an oral cavity.2. The oral care article of claim 1, wherein the first and secondnonwoven web comprise from about 10% to about 70%, by weight of thenonwoven webs, of surfactant.
 3. The oral care article of claim 2,wherein the surfactant comprises anionic surfactant, zwitterionicsurfactant, or a combination thereof.
 4. The oral care article of claim3, wherein the surfactant comprises alkyl sulfate and betaine compound.5. The oral care article of claim 1, wherein the backbone materialcomprises a synthetic polymer, a sugar alcohol, or a combinationthereof.
 6. The oral care article of claim 5, wherein the syntheticpolymer comprises polyvinyl alcohol.
 7. The oral care article of claim6, wherein the sugar alcohol is xylitol.
 8. The oral care article ofclaim 1, wherein the oral care article comprises an aesthetic agent. 9.The oral care article of claim 8, wherein the aesthetic agent comprisesflavors, sensates, sweeteners, salivation agents, or combinationsthereof.
 10. The oral care article of claim 1, wherein the first andsecond nonwoven webs comprise a meltblown filament.
 11. The oral carearticle of claim 10, wherein the meltblown filament has a basis weightof from about 20 g/m² to about 1000 g/m².
 12. The oral care article ofclaim 1, wherein the oral care article comprises a teeth whiteningagent, a tooth care agent, a mouthwash agent, a periodontal gum careagent, or combinations thereof.
 13. An oral care article comprising: a.a nonwoven web, the nonwoven web comprising: i. from about 10% to about80%, by weight of the nonwoven web, of one or more backbone materials,and ii. less than 10%, by weight of the nonwoven web, of water; and c. acoating composition sealed within a pouch formed by a folded nonwovenweb, the coating composition comprising fluoride; wherein the coatingcomposition is releasable from the oral care article upon exposure to anoral cavity.
 14. The oral care article of claim 13, wherein the firstand second nonwoven web comprise from about 10% to about 70%, by weightof the nonwoven web, of surfactant.
 15. The oral care article of claim14, wherein the surfactant comprises anionic surfactant, zwitterionicsurfactant, or a combination thereof.
 16. The oral care article of claim15, wherein the surfactant comprises alkyl sulfate and betaine compound.17. The oral care article of claim 13, wherein the backbone materialcomprises a synthetic polymer, a sugar alcohol, or a combinationthereof.
 18. The oral care article of claim 17, wherein the syntheticpolymer comprises polyvinyl alcohol.
 19. The oral care article of claim18, wherein the sugar alcohol is xylitol.
 20. The oral care article ofclaim 13, wherein the oral care article comprises an aesthetic agent.21. The oral care article of claim 20, wherein the aesthetic agentcomprises flavors, sensates, sweeteners, salivation agents, orcombinations thereof.
 22. The oral care article of claim 1, wherein thenonwoven web comprises a meltblown filament.
 23. The oral care articleof claim 22, wherein the meltblown filament has a basis weight of fromabout 20 g/m² to about 1000 g/m².
 24. The oral care article of claim 13,wherein the oral care article comprises a teeth whitening agent, a toothcare agent, a mouthwash agent, a periodontal gum care agent, orcombinations thereof.